U.S. patent application number 10/384913 was filed with the patent office on 2003-10-02 for apparatus for biaxially stretching a web of overwrapping material.
Invention is credited to Garwood, Anthony J.M..
Application Number | 20030185947 10/384913 |
Document ID | / |
Family ID | 46282096 |
Filed Date | 2003-10-02 |
United States Patent
Application |
20030185947 |
Kind Code |
A1 |
Garwood, Anthony J.M. |
October 2, 2003 |
Apparatus for biaxially stretching a web of overwrapping
material
Abstract
Packaging methods and apparatus for bonding a lidding web to a
tray web, characterized in that the lidding web is placed under
tension in both the longitudinal and lateral directions before
being bonded to a tray web. A tray web having recesses and channels
that form a conduit when the tray web is overwrapped with a lidding
web is provided. A lidding web has microperforations to control the
transfer of gases.
Inventors: |
Garwood, Anthony J.M.;
(Mercer Island, WA) |
Correspondence
Address: |
CHRISTENSEN, O'CONNOR, JOHNSON, KINDNESS, PLLC
1420 FIFTH AVENUE
SUITE 2800
SEATTLE
WA
98101-2347
US
|
Family ID: |
46282096 |
Appl. No.: |
10/384913 |
Filed: |
March 7, 2003 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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10384913 |
Mar 7, 2003 |
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PCT/US03/00167 |
Jan 2, 2003 |
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PCT/US03/00167 |
Jan 2, 2003 |
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10320863 |
Dec 16, 2002 |
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PCT/US03/00167 |
Jan 2, 2003 |
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10027929 |
Dec 20, 2001 |
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PCT/US03/00167 |
Jan 2, 2003 |
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10037440 |
Jan 2, 2002 |
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PCT/US03/00167 |
Jan 2, 2003 |
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09724287 |
Nov 28, 2000 |
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09724287 |
Nov 28, 2000 |
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PCT/US00/29038 |
Oct 19, 2000 |
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PCT/US00/29038 |
Oct 19, 2000 |
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09550399 |
Apr 14, 2000 |
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09550399 |
Apr 14, 2000 |
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09392074 |
Sep 8, 1999 |
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09392074 |
Sep 8, 1999 |
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09039150 |
Mar 13, 1998 |
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60040556 |
Mar 13, 1997 |
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Current U.S.
Class: |
426/392 |
Current CPC
Class: |
B65D 21/062 20130101;
B65D 81/268 20130101; A23B 4/12 20130101; B65D 21/066 20130101;
B65D 81/2076 20130101; B65D 81/267 20130101; B65D 81/28 20130101;
A23L 13/00 20160801; A23L 3/3418 20130101; A23B 4/24 20130101; A23B
4/00 20130101; A23B 4/16 20130101; B65B 7/164 20130101; B65D 81/264
20130101; B65B 25/067 20130101; B65D 77/2024 20130101 |
Class at
Publication: |
426/392 |
International
Class: |
C12C 003/04 |
Foreign Application Data
Date |
Code |
Application Number |
Nov 28, 2001 |
WO |
PCT/US01/45146 |
Claims
The embodiments of the invention in which an exclusive property or
privilege is claimed are defined as follows:
1. An apparatus for bonding a lidding web to a tray web, the
apparatus comprising a plurality of web-stretching assemblies, each
web-stretching assembly having a laterally translatable
web-gripping subassembly with a pivoting web-gripping jaw.
2. The apparatus of claim 1, wherein the web-stretching assemblies
are attached to an endless belt for movement in a longitudinal
direction.
3. The apparatus of claim 2, wherein each assembly comprises a pair
of web-gripping subassemblies laterally translatable relative to
each other.
4. The apparatus of claim 3, wherein each web-gripping subassembly
is laterally translatable.
5. The apparatus of claim 1, wherein the web-gripping subassembly
is attached to at least two independently actuatable members,
wherein one member controls the lateral movement of the
web-gripping subassembly, and one member controls the pivoting of
the web-gripping jaw.
6. The apparatus of claim 5, wherein each of the members comprises
a shaft, and wherein the apparatus further comprises: cam followers
attached to the distal ends of each shaft; and track portions
having cam tracks, said cam followers engaging the cam tracks to
move the shafts upon longitudinal movement of the web-stretching
assemblies.
7. The apparatus of claim 1, further comprising a cutting mechanism
assembly having at least one lateral blade portion and two vertical
blade portions, said cutting mechanism disposed in proximity to
said plurality of web-stretching assemblies to cut a web disposed
between two web-stretching assemblies.
8. An apparatus for bonding a lidding web to a tray web, the
apparatus comprising a plurality of web-stretching assemblies
mounted to an endless belt for movement in a longitudinal
direction, each web-stretching assembly having a laterally
translatable web-gripping subassembly with a pivoting web-gripping
jaw, wherein the web-gripping subassembly has at least two
independently actuatable members, wherein one member controls the
lateral movement of the web-gripping subassembly and one member
controls the pivoting of the web-gripping jaw.
9. The apparatus of claim 8, further comprising two of said endless
belts, with at least one conveyor disposed therebetween to carry
trays.
10. The apparatus of claim 9, further comprising a cutting
mechanism assembly located in proximity to the conveyors to cut a
web gripped between two web-gripping subassemblies, said cutting
mechanism having at least one lateral blade portion and two
vertical blade portions disposed to sever a lidding web from a tray
along the upper surface and opposite side surfaces of the tray.
11. The apparatus of claim 8, further comprising cam followers
attached to the distal ends of each member, and cam track plates
adjacent said timing belts, wherein said cam followers are engaged
in said cam tracks to move the members upon longitudinal movement
of the web-stretching assemblies.
Description
CROSS-REFERENCE(S) TO RELATED APPLICATIONS
[0001] This application is a divisional of PCT/US03/00167, filed
Jan. 2, 2003, which in turn is a continuation-in-part of
application Ser. Nos. 10/320,863, filed Dec. 16, 2002; Ser. No.
10/027,929, filed Dec. 20, 2001; Ser. No. 10/037,440, filed Jan. 2,
2002; PCT/US01/45146, filed Nov. 28, 2001, Ser. No. 09/724,287,
filed Nov. 28, 2000, which in turn is a continuation-in-part of
Application No. PCT/US00/29038, filed Oct. 19, 2000, now abandoned,
which in turn is a continuation of U.S. application Ser. No.
09/550,399, filed Apr. 14, 2000, now abandoned, which in turn is a
continuation-in-part of U.S. application Ser. No. 09/392,074, filed
Sep. 8, 1999, now abandoned, which in turn is a continuation of
U.S. application No. 09/039,150, filed Mar. 13, 1998, now
abandoned, which in turn claims the benefit of U.S. Provisional
Application No. 60/040,556, filed Mar. 13, 1997, and claims the
benefit of U.S. Provisional Application No. 60/129,595, filed Apr.
15, 1999; No. 60/141,569, filed Jun. 29, 1999; No. 60/144,400,
filed Jul. 16, 1999; No. 60/148,227, filed Jul. 27, 1999; No.
60/149,938, filed Aug. 19, 1999; No. 60/152,677, filed Sep. 7,
1999; No. 60/154,068, filed Sep. 14, 1999; No. 60/160,445, filed
Oct. 19, 1999; No. 60/175,372, filed Jan. 10, 2000; No. 60/255,684,
filed Dec. 13, 2000; No. 60/286,688, filed Apr. 26, 2001; No.
60/291,872, filed May 17, 2001; No. 60/299,240, filed Jun. 18,
2001; No. 60/312,176, filed Aug. 13, 2001; No. 60/314,109, filed
Aug. 21, 2001; No. 60/323,629, filed Sep. 19, 2001; No. 60/335,760,
filed Oct. 19, 2001; No. 60/373,222, filed Apr. 15, 2002; No.
60/373,232, filed Apr. 16, 2002; No. 60/385,710, filed Jun. 3,
2002; No. 60/388,067, filed Jun. 10, 2002; No. 60/391,702, filed
Jun. 24, 2002; No. 60/411,138, filed Sep. 16, 2002; No. 60/422,949,
filed Oct. 30, 2002; No. 60/424,388, filed Nov. 5, 2002; No.
60/427,516, filed Nov. 19, 2002; No. 60/429,644, filed Nov. 25,
2002; No. 60/433,526, filed Dec. 13, 2002. All the above
applications are herein expressly incorporated by reference in
their entirety for all purposes.
FIELD OF THE INVENTION
[0002] The present invention relates to the packaging of perishable
goods in a selected gas and most particularly packaging in low
oxygen environments.
BACKGROUND OF THE INVENTION
[0003] Methods of boning, grinding, and subsequent packaging of
beef in a substantially oxygen-free environment have been disclosed
in PCT/US01/45146. In one aspect, these steps occurred in an
essentially continuous and enclosed conduit. The method results in
a food item, such as beef, having high amounts of deoxymyoglobin.
The beef, high in deoxymyoglobin, is then packaged in oxygen free
individual trays and depending on the ultimate destination, may be
packaged in master containers. Master containers are used to
transport the individual beef packages in a substantially
oxygen-free state up to the point of sale. In either event,
however, it is desirable that oxygen is exchanged with the
controlled atmosphere within the individual packages prior to sale
to allow the beef to produce a bright red color, known as "bloom"
(or oxymyoglobin), that is visually pleasing to consumers. The
previous application disclosed trays with means, such as apertures
in the tray and in the overwrapping lidding webs at strategic
locations to provide for the rapid exchange of the controlled gas
within the packaged trays for the oxygen in air outside of the
packaged trays while restricting leaking of liquid therefrom. Other
ways of exchanging the controlled atmosphere for air and oxygen
included an oxygen permeable package that comprises a polypropylene
thermoformed tray with a plasticized polyvinyl chloride web
hermetically sealed to the flanges of the tray. In this manner, gas
exchange occurs by permeation through the permeable packaging
materials.
[0004] When a retail package with controlled atmosphere therein is
removed from an oxygen-free atmosphere and placed in the normal
ambient air atmosphere, the controlled gas in the free spaces on
the inside of the package is displaced by atmospheric gases over
time by the normal process of diffusion. It has been observed that
a deleterious phenomena can occur to the beef if the oxygen content
in the packages is not elevated from 0.05% to at least 3% oxygen
within about 15 minutes, and sometimes this effect occurs if the
oxygen content of the package is not elevated from 0.05% to at
least 10% oxygen within about 10 minutes. Without this rapid
elevation in oxygen content, it has been observed that the physical
and chemical mechanisms taking place on the surface of the beef
favor the production of increased amounts of undesirable
metmyoglobin relative to the desirable brightly colored red
oxymyoglobin. Therefore, it is advantageous to produce methods and
materials to exchange gases within the allotted time to reduce the
production of metmyoglobin and the unsightly appearance caused by
it.
[0005] Microperforated wrapping materials have been known and used
in the food industry; however, one drawback that has been observed
is "weeping" or the purge of liquids associated with the meat
contents through the microperforations. This weeping effects the
quality of the packaged meat in two ways. First, condensation from
the weeping liquids can accumulate on the internal surfaces of the
retail package. These water droplets can hinder the diffusion of
gases to the extent that the gas exchange can be slowed to several
hours. Second, previous attempts to use microperforated materials
as an overwrapping web material resulted in direct contact of the
microperforated web with the food item of the package. It was later
found that weeping of liquids through the package as a result of
this contact, occurred to such an extent that made it unacceptable
to consumers.
[0006] Therefore, there is a need to refine the methods and
materials useful in the packaging of perishable food items within
enclosed conduits, including the use of microperforated lidding
webs to provide a desired gas diffusion rate without allowing the
escape of liquids from the package. Also lacking in the prior art
are methods and apparatus that can apply longitudinal and lateral
tension on a web of lidding material. The present invention
fulfills these needs and provides further related advantages.
SUMMARY OF THE INVENTION
[0007] One aspect of the invention is a package having a first web
defining a cavity and a second web bonded to the first web, wherein
the second web includes microperforations at a location that is
specific to minimize the escape of liquids from the cavity to the
exterior of the package. In one particular embodiment, the first
web defines a four-sided cavity with walls, a flange, and
corresponding flaps attached to the flange that can be folded and
bonded to the cavity walls. The second web is an overwrapping
lidding web, wherein microperforations are provided on the lidding
web at a predetermined location. For example, the microperforations
are aligned with a flap recess, which in turn is in communication
with the interior of the tray cavity. In this manner, suitably
rapid gas exchange can occur with minimal to no escape of liquids
from the tray cavity.
[0008] Microperforations of the type that can be produced by lasers
can be introduced into the tray or to the overwrapping lidding web
materials to increase the gas exchange rate to within acceptable
limits to, in addition to rapid production of oxymyoglobin (bloom),
surpass the zone of rapid metmyoglobin formation.
[0009] Another aspect of the invention is a method of exchanging
the gas of a controlled atmosphere package with the ambient
atmospheric air by including microperforations in a web. In one
particular embodiment, a tray web with flaps is overwrapped with a
lidding web, wherein the lidding web is provided with the
microperforations at a predetermined location, more specifically,
adjacent a flap recess. In this manner the amount of weep is
reduced to acceptable quantities or may be eliminated
altogether.
[0010] Another aspect of the invention is a method of reducing or
substantially eliminating the amount of liquid weep from a package
by allowing accumulation of the liquid in a recess. In one
particular embodiment, a tray web with flaps is overwrapped with a
lidding web. The flap includes an enclosed recess that is in
communication with the tray cavity. The recess is overwrapped with
a lidding web. The lidding web holds the accumulated liquids within
the recess of the flap even though the lidding web may be
perforated. This is because a nonperforated section of the lidding
web, which may be in contact with the liquid, is located adjacent
the recess to hold the accumulated liquids therein.
[0011] Another aspect of the invention is a method of bonding a
stretched overwrapping lidding web to a tray web with flaps,
wherein the lidding web is bonded to the flaps in a substantially
horizontal position, and then the flaps are folded and bonded to
the tray walls.
[0012] Another aspect of the invention is a method of bonding a
stretched overwrapping lidding web to a tray web having at least a
first and a second flap, wherein the first flap is bonded to the
tray wall before the lidding web is bonded to the second flap,
wherein the second flap is in a substantially horizontal position.
The second flap is then bonded to the tray wall.
[0013] Another aspect of the invention is a method of trimming a
lidding web from a tray web wherein the tray includes a recess that
creates a gap when placed adjacent a second tray web, and allowing
better clearance for a trim device to trim the lidding web from the
adjacent tray webs.
[0014] Another aspect of the invention is a tray web forming a
cavity with vertical walls, wherein a recessed area is formed on a
portion of a flange surrounding the cavity. In this manner, a gap
is formed from two or more adjacent trays, such that the trim
device can properly cut the lidding web bonded to the trays.
[0015] Another aspect of the invention is a method of preventing a
contaminant from blocking or otherwise interfering with a bonding
surface of a tray web by covering the bonding surface with a guard.
Contaminants can include debris, particles, dirt, liquids, bits of
food, or any other items. In one particular instance, the guard
covers the bonding surfaces of the tray flange and the tray sides,
such as flaps, during the loading of food items, which were the
food item to contaminate the bonding surfaces, may block or
otherwise interfere with the integrity of the hermetic seal between
the tray web and an overwrapping lidding web bonded to the sides,
such as the flaps. In one instance, the flaps are folded within the
guard while loading the food item, and may be bonded to the tray
web. However, in other instances, after loading the food item in
the tray web cavity, the guard is removed and the flaps are
debonded, and moved to a horizontal disposition. Thereafter, an
adhesive is applied to the flange and flaps and a lidding web is
bonded thereto. The flaps may then be folded and bonded to the tray
web again.
[0016] In another aspect of the invention, a guard for covering the
bonding surface of a tray web includes walls to contain the tray
web. The guard also includes a portion to cover the tray flange
with a portion that extends into the tray cavity, but the guard
includes an opening giving access for loading the tray cavity.
[0017] Another aspect of the invention is a method of bonding a
stretched overwrapping lidding web to a tray web with flaps,
wherein the lidding web is bonded to the flanges at two opposing
ends of the tray and to two opposing flaps and wherein the flaps
are formed with a series of recesses and channels interconnecting
such recesses that allow direct communication between the tray
cavity and ambient atmosphere via the recesses formed in the
flaps.
[0018] Another embodiment of the invention is a method for bonding
a lidding web to a tray web or any other container, characterized
in that the lidding web is tensioned in the longitudinal and
lateral direction before the lidding web is bonded to the tray web,
or before the lidding web is applied to any bonding agent on the
tray web. The lidding web can be stretched longitudinally and
laterally. The lidding web can be horizontal at the first instance
of contact with the tray web upper surface. The lidding web can be
applied to the tray web without additional tensioning or relaxation
of the lidding web so as not to cause additional stretching or
contraction of the lidding web during application of the lidding
web to the bonding agent, so as to prevent smearing of the bonding
agent or the formation of creases in the lidding web. In one
embodiment, the lidding web can be shaped into an inverted channel
before applying the lidding web to the bonding agent on the tray
web.
[0019] Another embodiment of the invention is an apparatus for
bonding a lidding web to a tray web, wherein the apparatus has a
plurality of web stretching subassemblies, each web stretching
subassembly has a horizontally translatable web gripping
subassembly with a pivoting web gripping jaw. The web stretching
subassembly can be attached to a timing belt. The web gripping
subassembly is attached to a pair of independently actuatable
shafts, wherein one shaft operates the web gripping jaw, and the
other shaft operates the horizontal motion of the web gripping
subassembly. The shafts can have cam followers attached to the
distal ends of the shafts, wherein the cam followers ride on the
cam tracks and the cam followers follow the cam tracks.
[0020] Another embodiment of the invention is a method for
tensioning a lidding web in the longitudinal and lateral direction
prior to bonding to a tray web, characterized in that the
longitudinal tension is applied by gripping the edges of the
lidding web with a plurality of web gripping subassemblies, and
longitudinally pulling on the lidding web while the lidding web
supply is under tension. The lateral tension can be applied to the
lidding web by moving the web gripping subassemblies, which grip
the edges of the lidding web, apart in relationship to one another.
The lateral tension alternatively can be applied to the lidding web
by passing the lidding web over a pair of longitudinal members and
under a pair of longitudinal members wherein the spacing between
pairs diverges along the length of the members, and one pair will
terminate ahead of the other, so as to drop the lidding web to a
tray web.
[0021] Another embodiment of the invention is a method for
controlling the transfer of gases from packages and reducing the
amount of liquid weep from packages, characterized by overwrapping
a tray web containing goods with a lidding web, wherein the lidding
web has an area of microperforations adjacent a web tray recess
that is in communication with a web tray cavity.
[0022] Another embodiment of the invention is a tray having a web
with sides and a base to provide a cavity and defining a series of
recesses with connecting channels on one side of the web, wherein
the channels and recesses provide a conduit for gases from the web
cavity to the exterior thereby allowing transfer of the gases and
minimization of liquid loss when a second web is bonded at least
over the cavity and sides.
[0023] The present invention provides numerous advantages. In one
instance, the amount of metmyoglobin formed on the surfaces of beef
food items is reduced. Other aspects of the present invention
increase the throughput of trays in the packaging conduit. For
example, by providing a gap between adjacent tray webs, more trays
per unit area of conveyor are allowed in the packaging conduit,
because the gap allows for the clearance needed by a trimming
device, thus averting the spacing of tray webs farther apart on the
conveyor. By folding the leading and trailing flaps of trays before
entering the packaging conveyor, more trays per unit area of
conveyor are allowed in the packaging conduit. By using an enclosed
packaging conduit, the need to use a vacuum chamber to provide a
controlled atmosphere on a tray by tray basis is eliminated.
BRIEF DESCRIPTION OF THE DRAWINGS
[0024] The foregoing aspects and many of the attendant advantages
of this invention will become more readily appreciated as the same
become better understood by reference to the following detailed
description, when taken in conjunction with the accompanying
drawings, wherein:
[0025] FIG. 1 shows a cross section illustration of a packaging
conduit according to the present invention;
[0026] FIG. 2 shows a top plan illustration of a packaging conduit
according to the present invention;
[0027] FIG. 3 shows a side illustration of two adjacent tray webs
according to the present invention;
[0028] FIG. 4 shows a top plan illustration of a packaging conduit
according to the present invention;
[0029] FIG. 5 shows a perspective illustration of a sealed package
according to the present invention;
[0030] FIG. 6 shows a top plan illustration of a tray web portion
according to the present invention;
[0031] FIG. 7 shows a cross section illustration of tray and
lidding webs according to the present invention;
[0032] FIG. 8 shows a detailed illustration of a tray web
communication portion with serrations between a tray web cavity and
a flap recess according to the present invention;
[0033] FIG. 9 shows a perspective illustration of a flange guard
according to the present invention;
[0034] FIG. 10 shows a cross section illustration of a flange guard
and tray web according to the present invention;
[0035] FIG. 11 shows a perspective illustration of a tray web with
channels formed into the tray web side walls according to the
present invention;
[0036] FIG. 12 shows a side view illustration of a tray web with
channels formed into the side walls according to the present
invention;
[0037] FIG. 13 shows an end view illustration of a tray web
according to the present invention;
[0038] FIG. 14A shows a diagrammatic plan view illustration of an
apparatus for applying a biaxially stretched web of material to the
upper surface and side walls of a tray web according to the present
invention;
[0039] FIG. 14B shows a cross-sectional illustration of the
apparatus of FIG. 14A;
[0040] FIG. 14C shows a cross-sectional illustration of the
apparatus of FIG. 14A;
[0041] FIG. 14D shows a cross-sectional illustration of the
apparatus of FIG. 14A;
[0042] FIG. 15 shows a perspective illustration of an apparatus for
applying a biaxially stretched web of material to the upper surface
and side walls of a tray web according to the present
invention;
[0043] FIG. 16 shows a cross section illustration of the web
stretching arrangement in an apparatus for applying a biaxially
stretched web of material to the upper surface and side walls of a
tray with channels formed therein according to the present
invention;
[0044] FIG. 17 shows a cross section illustration of the web
stretching arrangement in an apparatus for applying a biaxially
stretched web of material to the upper surface and side walls of a
tray web according to the present invention;
[0045] FIG. 18 shows a plan view illustration of the web stretching
arrangement in an apparatus for applying a biaxially stretched web
of material to the upper surface and side walls of a tray with
channels formed therein according to the present invention;
[0046] FIG. 19 shows a perspective illustration of the web
stretching arrangement in an apparatus for applying a biaxially
stretched web of material to the upper surface and side walls of a
tray according to the present invention;
[0047] FIG. 20 shows a side elevation illustration of a biaxial
stretch packaging apparatus according to the present invention;
[0048] FIG. 21 shows a plan view illustration of a biaxial web
stretching apparatus according to the present invention;
[0049] FIG. 22 shows an isometric illustration of a web stretching
subassembly with web gripping subassembly and cam track portions
according to the present invention;
[0050] FIG. 23 shows a cross-sectional view illustration, A--A,
across web stretching subassembly shown in FIG. 21;
[0051] FIG. 24 shows a cross-sectional view illustration, B--B,
across web stretching subassembly shown in FIG. 21;
[0052] FIG. 25 shows a cross-sectional view illustration, C--C,
across web stretching subassembly shown in FIG. 21;
[0053] FIG. 26 shows a cross-sectional view illustration, D--D,
across web stretching subassembly shown in FIG. 21;
[0054] FIG. 27 shows a cross-sectional view illustration, E--E,
across web stretching subassembly shown in FIG. 21;
[0055] FIG. 28 shows a cross-sectional view illustration, F--F,
across web stretching subassembly shown in FIG. 21;
[0056] FIG. 29 shows a cross section illustration of a guard and
tray web according to the present invention;
[0057] FIG. 30A shows a diagrammatic plan view illustration of an
apparatus for applying a biaxially stretched web of material to the
upper surface and side walls of a tray web according to the present
invention;
[0058] FIG. 30B shows a cross-sectional illustration of the
apparatus of FIG. 30A;
[0059] FIG. 30C shows a cross-sectional illustration of the
apparatus of FIG. 30A;
[0060] FIG. 30D shows a cross-sectional illustration of the
apparatus of FIG. 30A;
[0061] FIG. 31 shows a cross section illustration of the web
stretching arrangement in an apparatus for applying a biaxially
stretched web of material to the upper surface and side walls of a
tray with channels formed therein according to the present
invention;
[0062] FIG. 32 shows a cross section illustration of the web
stretching arrangement in an apparatus for applying a biaxially
stretched web of material to the upper surface and side walls of a
tray web according to the present invention;
[0063] FIG. 33 shows a plan view illustration of the web stretching
arrangement in an apparatus for applying a biaxially stretched web
of material to the upper surface and side walls of a tray with
channels formed therein according to the present invention;
[0064] FIG. 33 shows a plan view illustration of the web stretching
arrangement in an apparatus for applying a biaxially stretched web
of material to the upper surface and side walls of a tray with
channels formed therein according to the present invention; and
[0065] FIG. 34 shows a plan view illustration of the web stretching
arrangement in an apparatus for applying a biaxially stretched web
of material to the upper surface and side walls of a tray with
channels formed therein according to the present invention.
DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT
[0066] The aforementioned application PCT/US01/45146, entitled
CONTINUOUS PRODUCTION AND PACKAGING OF PERISHABLE GOODS IN LOW
OXYGEN ENVIRONMENTS, filed Nov. 28, 2001, is herein expressly
incorporated by reference in its entirety for all purposes.
[0067] Referring to FIG. 1, one embodiment of a packaging conduit
includes a frame 114 for carrying the conduit 100. Conduit 100 is
substantially enclosed to contain any suitable gas or combination
of gases, including carbon dioxide, carbon monoxide, or nitrogen or
any liquid thereof. However, in other embodiments, oxygen in any
proportions greater or less than that found in air can be used. The
packaging conduit 100 includes a conveyor 102 for carrying trays
104 containing perishable food items. Conveyor 102 may include a
continuous conveyor section running the length of the entire
conduit or may be divided into a plurality of more than one
conveyor section. The advantage of having more that one conveyor
section is to provide different conveyor speeds. This is useful as
will become apparent from the disclosure below to "bunch" adjacent
trays together at a desirable location, thus increasing the
throughput of the packaging conduit and minimizing the amount of
lidding web material used by eliminating scrap lidding sections
that would otherwise occur. Conveyor 102 may include a continuous
flat belt on which trays 104 rest or conveyor 102 may include
cleats or brackets to hold trays 104 in position. Flat, smooth
belts may allow the sliding of packages in the manner described to
bunch trays in close proximity or adjacent one another.
Alternatively, the tray carrying the conveyor may comprise of a
pair of parallel belts, such as 2316 in FIG. 23, each having a
cross-sectional profile that enhances contact friction and
resultant adhesion with the underside of each tray, wherein the
pair of belts are spaced apart so as to enable improved tray
stability.
[0068] Packaging conduit 100 includes first and second gripper
chains 110 disposed adjacently on either side of conveyor 102, for
at least a portion of the conveyor length. Gripper chains 110
extend along a portion of the conveyor 102 wherein bonding of an
overwrapping lidding web takes place. The path traveled of the
gripper chains 110 is adjusted by any number of sprockets 116 to
direct motion of gripper chains substantially parallel to conveyor
102 or perpendicular or at any desirable angle. The packaging
conduit 100 includes a supply of lidding web material 106. Lidding
web material is provided in a roll 106 and can be outside of the
packaging conduit 100, and openings 112 are provided to allow the
passage of lidding web 108 and gripper chain 110 into and out of
the packaging conduit 100. Openings 112 can be desirably configured
to minimize the escape of any suitable gas within the packaging
conduit 100. In one particular instance, gripper chains 110 can
take hold of lidding web 108 at either edge thereof at sprocket
118. Gripper chains 110 can apply tension to the lidding web 108
thereto in a transverse direction to the packaging conduit 100.
Longitudinal tension may be applied to the lidding web 108 by
applying a braking action to the roll of lidding web material 106,
while gripper chains 110 pull the lidding web 108 forward. Lidding
web 108 is carried into the packaging conduit 100 wherein the
lidding web 108 is bonded to surfaces of the tray web 104,
including any flange and flaps.
[0069] One aspect of the invention is a method of bonding a
stretched lidding web 108 to a tray 104 with flaps, wherein the
lidding web 108 is bonded to the flaps, while the flaps are in a
substantially horizontal position. Once the lidding web 108 is
bonded to the flaps, the flaps are next folded and bonded to the
tray wall. This operation results in an advantage over other
methods that first bond the flaps to the tray and thereafter bond
the lidding web to the folded and bonded tray flaps. According to
the invention, the lidding web can be tensioned after being bonded
to flaps when the flaps are folded into the side locations of the
tray.
[0070] Another aspect of the invention is a method of bonding a
stretched lidding web 108 to a tray 104 having at least a first and
second flap, wherein the first flap is bonded to the tray wall
before the lidding web 108 is bonded to the second flap, wherein
the second flap is in a substantially horizontal position to the
tray. In this instance, bonding the lidding web to the first tray
flap is optional, since the bond of the lidding web to a tray
flange is adequate to provide for hermetic sealing of the
package.
[0071] Another aspect of the invention is a method of trimming a
lidding web 108 from a tray 104, wherein the tray includes a
recessed region around the outer periphery of the tray flange. Thus
when two or more trays are in adjacent disposition, a gap is formed
allowing the proper clearance access to a lidding web trimming
device between the adjacent trays. This results in numerous
advantages. For example, trays can be spaced closer to one another
resulting in less waste of the lidding material and increased
throughput on the packaging conduit conveyor so long as there is
sufficient clearance for a trimming device to transversely and
longitudinally cut the lidding web 108. In one particular instance,
the adjacent trays 104 can be positioned so as to be touching or
nearly touching any adjacent trays. In this instance, suitable
clearance is provided by the gap between trays to allow the
trimming device access to trim the lidding web 108 between adjacent
trays 104 resulting in very little waste of lidding web material
and increased throughput.
[0072] A further aspect of the invention is a package assembled
from a tray web with flaps with a cavity wherein the lidding web is
bonded to the tray and the lidding web includes microperforations
at specific locations to minimize the escape of liquids produced by
the perishable food item.
[0073] A further aspect of the invention is a method of preventing
a contaminant from blocking or otherwise interfering with a bonding
surface of a tray web by covering the bonding surface with a guard.
Contaminants can include debris, particles, dirt, liquids, bits of
food, or any other items common to or used in a packaging
operation. In one particular instance, the guard covers the tray
flange of a tray web during loading of food items, which may block
or otherwise interfere with the integrity of the hermetic seal
between the tray flange and an overwrapping lidding web bonded to
the flange if the food item were to contaminate the bonding
surfaces of the flange. In another embodiment, the guard covers the
tray sides, such as flaps, of a tray web during the loading of food
items that may block or otherwise interfere with the integrity of
the hermetic seal between the tray sides, such as flaps, and an
overwrapping lidding web bonded to the sides, such as the tray web
flaps. In one instance, the flaps are folded within the guard while
loading the food item, and may be bonded to the tray web. However,
in other instances, after, loading the food item in the tray web
cavity, the guard is removed and the flaps are debonded, and moved
to a horizontal disposition. Thereafter, an adhesive is applied to
the flange and flaps and a lidding web is bonded thereto. The flaps
may then be folded and bonded to the tray web again.
[0074] Referring now to FIG. 2, one suitable embodiment of a
lidding web 202 and a top side view of a packaging conduit 200 is
illustrated. It is to be appreciated that while one row of trays
for a packaging conduit is illustrated, any number of tray rows can
be provided in a packaging conduit, the single tray row being
merely one example. In one embodiment, lidding web 202 can include
two areas 204 and 206, respectively, placed at opposite edges of
the lidding web 202. Areas 204 and 206 can be areas containing
microperforations or alternatively and/or additionally can include
printed material. However, it is to be readily appreciated that the
combination of areas 204 and 206 as shown is merely one example of
where microperforations can be placed on the lidding web based on
one configuration of a tray with flaps. It is to be readily
appreciated that other areas not shown in the figure can also
include microperforations, the combination of areas 204 and 206
being an example of one embodiment.
[0075] Referring now to the top side view of the packaging conduit
200, a section of the apparatus wherein the two horizontally
disposed gripper chains 208 and 210 carry a firmly stretched
lidding web therebetween, such as lidding web 202, is illustrated.
Lidding web 202 is carried substantially horizontally and directly
above a conveyor carrying trays 216 containing food items. In one
instance, each tray 216 can have four flaps for side walls;
however, by this view, the flaps disposed on the leading and
trailing ends of the trays 216 have been bonded to the tray cavity
walls and thus they are not shown. Alternatively, the trays 216 can
eliminate the leading and trailing flaps and have only the two
opposite side flaps 212 and 214. In this instance, a tray flange
218 disposed around the perimeter of the tray cavity will provide
sufficient surface area to adequately bond to the lidding web
material 202, thus providing a hermetic seal. In either event,
flaps 212 and 214 are positioned in a substantially horizontal
disposition, which is substantially aligned with the tray flange.
Adhesive is applied to the tray flange and flap areas by any
suitable application device. Lidding web 202 is then bonded
thereto. Following bonding of the lidding web 202 to the tray
flange 218 and flaps 212 and 214, adhesive is applied to the
underside of flaps 212 and 214, which are then folded and bonded to
the vertically disposed side walls of the tray cavity 216. Lidding
web 202 can be perforated and/or printed at sections 204 and 206 as
required, either before bonding to the tray or in some instances
can be perforated or printed after bonding to the tray thereto.
Trimming devices will suitably cut the web both longitudinally and
transversely. Any remaining scrap lidding web 208 can be discarded
or recycled, and reused as desired. One particular benefit of
bonding the two leading and trailing flaps that come before and
after adjacent trays or alternatively eliminating them is that
trays may be stacked closer to one another. In this manner, the
throughput of trays through the packaging conduit 200 is increased.
Another benefit is that the amount of lidding web 202 used per
package is reduced because the amount of spacing between trays is
also reduced, leading to fewer quantities of scrap lidding web.
However, in other alternatives of the present invention, the
leading and trailing flaps of the trays may be bonded to a lidding
web. Suitable materials for tray webs and lidding webs and methods
for making them have been described in the aforementioned PCT
application.
[0076] It should be appreciated that once the lidding web is
applied to any suitable package, the assembled package can further
be packaged within a master container, which may contain a
plurality of like packages. In one embodiment, the master container
keeps the individual packages in a substantially oxygen deficient
environment until the individual packages are ready to be shelved
for display to consumers, whereas in another embodiment, the
environment may comprise an oxygen enriched gas blend. While the
individual packages remain in the master container there may be
exchange of gases from within the individual packages with the
interior of the master container. When the individual packages are
removed from the master container to the normal ambient atmosphere
containing higher quantities of oxygen, the controlled atmosphere
within the packages is displaced by air including oxygen. Under
some circumstances, the individual packages may not be stored in a
master container, in which case, a form of peelable tab can be
applied to the area of microperforations to prevent the premature
displacement of controlled atmosphere gas. In this case, the tab
may be hermetically sealed to the lidding web by suitable
adhesives. The tab is pulled just prior to the packages being
shelved for consumer display, exposing the microperforations, and
initiating the exchange of gas therethrough.
[0077] Referring now to FIG. 3, one particular aspect of trays to
increase the capacity of a packaging conduit is shown. Tray webs
300 and 301 with flaps 304 and 305 are shown in nearly touching or
actual touching disposition, wherein flaps 304 and 305 are folded
and bonded to trays 300 and 301, respectively, on a wall thereof.
Trays 300 and 301 are travelling on the conveyor 302 and can be
bunched by providing conveyor runs at varying speeds. For example,
a conveyor at a relatively higher speed is followed by a conveyor
at a relatively low speed. Flaps 304 and 305 are shown with a gap
clearance 310 created by recessing a portion of the outer periphery
edge of the tray web at locations 314 and 316, respectively, in
flaps 304 and 305. Recesses 314 and 316 may be any suitable shape
which when abutted against one another will create the gap 310.
Recesses 314 and 316 may be any suitable dimensions to allow a
desired trimming device, such as slitter device 312, access to cut
the lidding web 308. Gap clearance 310 can be provided at any
location where two adjacent trays are in close or touching
proximity to one another. In this instance, trays 300 and 301 can
be spaced in relatively close proximity to one another while
allowing the trimming device 312 ample clearance to operate
properly. Benefits provided by the present invention is that trays
may be closely spaced to each other on the conveyor 302, thus
increasing the throughput of packages through the packaging conduit
and reducing the amounts of wasted lidding material.
[0078] One suitable method for creating the recesses 314 and 316 in
tray webs 300 and 301 is thermoforming. In thermoforming, suitable
molds can be provided which can be arranged as the negative of the
eventual tray web. In one instance, raised projections can be
provided at a location adjacent or in close proximity to what will
become the outer edge periphery of the tray web or at a portion
connecting the tray flange with the respective flaps, such as a
hinge. Thus, when ejected from the mold, the projections show up as
recesses in the tray web, wherein the recesses appear on what will
become the outer edge periphery when the package is assembled. In
one particular instance, flaps 304 and 305 have been molded to
include a recess running lengthwise and front and back of the trays
300 and 301, such that the recesses 314 and 316 are transversely
positioned when the tray is arranged in the packaging conduit 100
of FIG. 1, for example. However, recesses 314 and 316 can be
provided around the entire periphery or on three sides for other
packaging conduit configurations. For example, in the illustration
provided in FIG. 4, two lanes of trays are provided. Therefore, any
tray is adjacent three other trays, and thus in this instance, a
suitable tray, such as tray 104 surrounded by trays 118, 120 and
122 can have three or more sides having recesses to allow gap
clearances for suitable lidding web cutting devices. In this
instance, tray 104 can have a gap clearance along the longitudinal
direction as well as gaps provided in the transverse direction. In
this manner, trays can be provided closely spaced to each other on
the conveyor in two or more lanes while providing ample clearance
for cutting device 124 to operate properly. Cutting device 124 can
have a plurality of longitudinally oriented blades to cut the
lidding web in the longitudinal direction on either side of trays,
as well as have a transverse blade to cut the lidding web in a
transverse direction before and after adjacent trays.
[0079] It is to be appreciated that a twin lane stretch sealing
machine as depicted is merely one example of the present invention.
It is to be appreciated that one, two or more lanes of trays can be
provided on the conveyor, the specific configurations shown in
FIGS. 3 and 4, being merely examples of the present invention.
[0080] Referring now to FIG. 5, a three-dimensional view of a
corner of a tray with flaps constructed according to the present
invention is shown. The tray web 500 has been assembled as a
completed package with a food item 545, such as ground beef, for
example, placed therein. The tray 500 includes a tray cavity, which
contains the food item 545. The tray 500 includes a flange 544
constructed around the periphery of the tray cavity. The flange
upper surface is generally substantially horizontal. The tray 500
includes a first flap 543 and a second flap 546, attached to the
tray flange 544 at a tray hinge 549. While only first and second
adjacent flaps are shown, it is to be appreciated that oppositely
placed third and fourth flaps 543 and 546 can be similarly
configured. The tray 500 includes a communication structure 540,
which allows the exchange of gases from the tray cavity to a
recessed portion of the outward facing side of the second flap 546.
The flap recess is bordered by a raised surface at location 550,
which borders the recess 547, but for the area of the communication
548 to allow for free gas passage therethrough. In this instance,
the communication 540 includes serrations formed on the tray flange
544, which may extend downward and include the tray hinge 549.
[0081] A lidding web is bonded to the tray 500 in the following
manner. A bead of adhesive is provided to unite the cavity and the
flap recesses as a continuous space closed to the outside with a
lidding web. A bead of adhesive 541 is provided at the tray flange
544, such that the adhesive is applied to the upper surfaces of the
flange 544. The bead of adhesive 541 continues downward from the
communication at location 560. The bead of adhesive 541 is applied
to the flap surfaces that border the flap recess 550 at locations
562. While only a portion of the tray with flaps is shown, it is to
be appreciated that an adhesive bead is provided in a similar
manner on the opposite side of the flap 546 so that when the
lidding web is bonded thereto, the tray cavity forms a continuous
united space with the outward facing recess on at least one of the
tray flaps.
[0082] A lidding web 544 is stretched and applied to the adhesive
to form a seal between the tray web and the lidding web and the
flap and the lidding web. In this manner, a continuous space is
created from the tray cavity and the flap recess that is connected
via the communication 540. The lidding web is microperforated at
the area 547 that is placed adjacent the flap recess. In this
manner, gas exchange can take place at the location of
microperforations 547. Gas exchange is further enabled by the
serrations 540, which provide for passages from the tray cavity and
the flap recess, thus, enabling gas exchange of the tray cavity
with the exterior atmosphere, such as is desired before placing the
package for retail sale. The area of microperforations 547 may be
smaller than the area of the flap recess. Microperforations can
begin at a distance above the lowermost edge of the recess, thus
leaving a portion of nonperforated lidding web between the
lowermost recess edge and the area of microperforations 547. In
this manner, any liquids that pass from the tray cavity into the
flap recess via the communication accumulate at the bottom of the
flap recess and are kept out of contact from the microperforations;
therefore the liquid does not weep from the microperforations. The
lidding web is bonded to the tray corner with a bead of adhesive
556 that is provided to bond any loose edges 551 and 554 of lidding
web to the tray corners.
[0083] Referring now to FIG. 6, a top plan view of a section of a
tray web with flaps is shown. While only two flaps are shown, one
end flap 601 and one side flap 605, it should be readily
appreciated that oppositely arranged third and fourth flaps are to
be of substantially similar configuration to the flaps shown. A
centrally located cavity 603 is enclosed by the four vertically
disposed walls of the tray web, only two of which are shown. The
cavity is bordered by a flange 607, substantially continuous and
flat at all upper surfaces but for the communication structure 604.
In the communication structure 604, the flange 607 is provided with
serrations 604, which readily allow gases to pass therethrough into
a flap recess 606 via an opening passage 609. The flange 607, which
extends around the periphery of the cavity 603, is formed from the
tray web. Each tray flap is attached to the flange 607 at a
respective hinge 608 which allows the flap to be folded in a
downward arcing motion in preparation for bonding to the tray
walls. Flaps 601 and 605 are shown to be substantially horizontally
disposed in relation to the tray and tray flange 607. Flaps 601 and
605 include a centrally disposed recess portion 606 bordered by
raised areas. The outermost limit of the recess is shown by the
line with the reference numeral 622. The raised border areas are
then bounded by line 622 and the line with reference numeral 624;
thus line 622 marks the boundary of the recess area 606. The border
area is open to the recess area 606 at location 609; thus allowing
recess 606 to communicate with the tray cavity 603 therethrough.
The raised border area surrounding the recess 606 is substantially
horizontal with the flange upper surface while the flap 605 is
positioned as shown, and thus the flange 607 and the border areas
can be provided with any suitable adhesive. A continuous bead of
adhesive is applied along a path 602 including the flange 607 and
the flap 605, and the raised border areas surrounding recess 606.
The adhesive bead 602 is applied in a manner to unite the cavity
603 and the flap recess 606 into a substantially single space when
enclosed by the tray and lidding webs. The spaces created by the
cavity 603 and the flap recess 606 are joined by communication 609
and opening 604. The adhesive bead 602 is applied around the
communication 604 and 609 and continues to the raised borders of
the flap recess 606. The adhesive bead continuous on an opposite
side of the communication 604 on flange 607 so as to form a
continuous bead of adhesive enclosing the spaces defined by the
cavity 603, the flap recess 606, and the communication 604 and 609
between these two spaces. When a web of overwrapping lidding web is
applied on the tray and flaps to the adhesive bead, the tray cavity
603 is joined to the flap recess 606 as a continuous enclosed space
joined by the communication 604 and 609. Communication structure
604 includes serrations formed on the flange 607, which may extend
to the hinge 608 and portion of the flap 605. Flaps 601 and 605 may
be bonded to the tray with discontinuous. adhesive beads 620
applied at flap corner edges. Likewise, lidding web may be bonded
to the flap corners with adhesive beads at locations 620 with
discontinuous adhesive beads.
[0084] While the particular communication between the cavity and
recessed flap area has been shown to include serrations, it is to
be appreciated that other methods of establishing communication
between the tray web cavity containing the goods and the flap may
be used in the practice of the present invention, serrations being
one example. It is also to be appreciated that other methods may
include apertures from the tray cavity to the flap.
[0085] The overwrapping lidding web applied to the tray includes an
area shown bounded by the dashed line with reference numeral 619.
In one instance, the area bounded by line 619 is microperforated by
suitable laser means, for example, such that liquids and any
pathogens are restricted from passing therethrough, but gases such
as atmospheric oxygen and air can pass directly through the
microperforated section into the recess, through the communication
at 609 and 604, and into the tray cavity 603. Likewise, any
controlled atmosphere packaging gases contained within the cavity
603 can pass through the communication 604 with serrations and
opening 609 into the flap recess 606 and out through the
microperforated area bounded by the line 619. As can be seen, the
area bounded by the line 619 is smaller than the area bounded by
622, the later marking the boundary of the recess area 606. Thus it
is advantageous to provide an area between the microperforated area
619 and the boundary of the recess 622 that does not include
perforations. In this manner, any liquids which pass into the
recess 606 will accumulate at the bottom of the cupped recess
(i.e., the nonperforated area between lines 622 and 619). While an
area of microperforations has been shown to nearly extend to the
boundaries of the recess, it is to be appreciated that the eventual
area of the microperforations will be determined experimentally.
For instance, the size, number, and the spacing of the
microperforations may influence the eventual size of the
microperforated area. The area shown here is merely one example, of
a suitable microperforated area. Furthermore, one or more flaps may
include areas with microperforations. In addition, tray cavity
walls and flaps may alternatively or additionally be
microperforated in any location thereof in accordance with the
invention to provide gas exchange without release of liquids.
[0086] Referring now to FIG. 7, a cross section through a tray web
700 with a lidding web 731 sealed thereto is shown. The tray 700
includes a tray cavity 732 with cavity walls extending upward and
substantially vertically or at a small incline from the cavity base
767. It should be readily appreciated that other walls and flaps
form the remainder of the tray with flaps, the portion shown in the
figure, being merely an example of one suitable flap with recess
bonded to a lidding web with microperforations. A flap 733 is
bonded to the tray cavity wall by a bead of adhesive applied at
location 736. An outward facing side of the flap 733 defines a
recess 738. The recess 738 is bounded by raised borders 739. A
lidding web 731 is bonded to the tray flange at the upper surface
thereof with an adhesive 735. The lidding web 731 is also bonded to
the borders 739 surrounding the recess 738 with adhesives 735.
Adhesive is therefore placed at locations 735 on an upper surface
of the tray flange and at vertical surfaces of the flap adjacent
the flap recess 738 at upper and lower borders 739 thereof. A
passage or communication is provided between the tray cavity 732
and the flap recess 738 at the communication 604 and opening 609 as
shown in FIG. 6. An area of lidding web 731 denoted by reference
numeral 730 includes microperforations. In one instance, the area
730 is spaced a distance from the lower boundary of the flap recess
738 at location 734. In this manner, any liquids that may flow from
the tray cavity 732 into the recess 738 are prevented from exiting
and the liquids accumulate in the flap recess 738. The liquids are
retained within the flap recess 738 by the lidding web 731 that is
nonperforated and is located between the lower most boundary of the
microperforated area 730 and the lower boundary of the flap recess
734 below location 734. In this manner, liquids are substantially
kept away from microperforated areas and prevented from exiting to
the exterior of the package. Thus, one advantage of the present
invention is the elimination of liquid weep.
[0087] Referring now to FIG. 8, one example of a gas exchange
communication structure between a tray cavity and a flap recess is
shown. The communication 800 is formed in a tray flange 823. The
tray flange 823 is shown to be recessed, wherein the recessed
portion can accommodate serrations 821 therein. The serrations can
be the full width of the flange 823 or the serrations can be less
than the full width of the flange 823 to leave a flat area. The
serrations can be located at either the inner edge or the outer
edge of the flange 823. The serrations can also continue downward
or throughout the thickness of the tray flange 823. The serrations
maintain the lidding web 822 from collapse around the communication
800, yet allow the passage of gases therethrough. While one example
of gas exchange communication has been shown and described, it is
to be appreciated that other communication structures between tray
cavities and flap recesses are within the scope of the present
invention. For example, numerous communication passages and
apertures and other examples of communicating between a tray cavity
and a flap recess can be provided.
[0088] Referring now to FIG. 9, a guard 900 for covering a tray web
is illustrated. The guard is used in preventing a contaminant, such
as a food item, from blocking or otherwise interfering with a
bonding or sealing surface of a tray web by covering the bonding
surface during packaging, including during the loading of the food
item within the tray cavity. The guard 900 includes walls 902,
vertically disposed and connected to adjacent walls at a corner
section, thus forming a box like structure having no bottom. While
only a first and a second wall are shown, it is apparent that the
opposite third and fourth walls are configured similar to the two
that are shown. The height and length of guard walls 902 can be
adjusted to coincide with any suitable tray web height and length,
including a tray web with flaps. It is also appreciated that the
guard 900 can be configured and adjusted in any manner to contain
the tray web with the flaps in a folded disposition, meaning the
flaps of the tray web have been placed adjacent the tray cavity
prior to placing the guard on the tray web. The guard 900 can also
be configured to be used while the flaps are in an open
disposition, meaning the flaps are not adjacent the tray web. Upper
portions of the walls 902 extend inwardly and horizontally forming
a horizontal shelf 903 to coincide with the flange of any suitable
tray web. The horizontally extending shelf 903 terminates
substantially coextensively with the tray cavity to provide an
opening for accessibility to the tray cavity during loading.
However, the shelf 903 may extend further in toward the tray
cavity, and in some instances includes a lip that extends into the
tray cavity. It is to be appreciated that some amount of
misalignment when placing the guard over a tray web can be
tolerated, and thus the walls and shelf need not be exactly
dimensioned to the tray web.
[0089] Referring now to FIG. 10, a cross section of a guard 1000
and tray web 1002 defining a cavity 1004, flange 1008, and flap
1005, is illustrated. Tray web flap 1005 is in close and sometimes
firm contact with the internal sides of guard walls 1000. Guard
1000 includes a horizontal shelf 1006 at an upper portion of the
guard walls 1000. Shelf 1006 is directed inward from walls and
terminates to form an opening 1002 to provide accessibility to the
tray cavity 1004 for loading of the food item. Wall 1000 covers
flap 1005 at an exterior side thereof during packaging, including
loading a food item. Shelf 1006 covers flange 1008 at an upper
surface thereof during packaging, including loading a food item.
Shelf 1006 includes a lip 1003. Lip 1003 is formed vertically to
partly enter the tray cavity 1004. Any amount of protrusion of lip
1003 into the tray cavity is advantageous, as the lip 1003 prevents
contaminants from contact with the flange 1008.
[0090] If the food item were to spill in the area of the flap or
flange bonding surfaces, the spilled food item would block or
otherwise interfere with a hermetic seal from being formed thereon.
The guard thus prevents spillage of a food item upon the flap or
flange bonding surfaces.
[0091] Referring now to FIG. 29, a cross-sectional view of a guard
2900 and tray web 2902, defining a cavity 2904 loaded with goods
2906, such as food items, for example, is illustrated. Tray web
2902 rides on conveyor 2908 and the guard 2900 is positioned
adjacent the tray web 2902. The guard 2900 has a horizontal shelf
2912 extending above the tray web flap 2916. The tray web flap's
profile follows an arcuate path so that spaces are created between
the tray web flap 2916 and the inner surfaces 2918 of the guard
walls and horizontal shelf. The horizontal shelf 2912 terminates in
a downwardly projecting lip 2910. The lip 2910 extends into the
tray cavity and is adjacent the inner upper portion of the tray web
flap. In this manner, an adhesive bead 2914 can be located on the
exterior of the tray web flap 2916 and the guard 2900 prevents any
contaminants from interfering with the bonding agent located on the
tray web 2902.
[0092] The guard can be made using conventional plastic or metal
materials. In one instance, the guard can be made from plastic by
injection molding. However, the guard can also be made by
thermoforming. The guard is reusable after each use by sanitizing
in an appropriate manner. The guard can be manually placed on the
individual tray webs during packaging, and before loading of any
food items. However, in other instances, the guard can be
automatically placed by machine over the tray webs. The guards can
be attached to a continuous conveyor, wherein the trays are located
within the guard at a first location on the conveyor and the trays
are removed at a second location, such as where the trays can enter
a stretch sealing apparatus, for example. In one instance, if the
tray web includes flaps, the flaps may be folded, and additionally
or alternatively bonded to the tray web side walls before placement
of the tray web within the guard. In another instance, the flaps
can be lightly bonded to the tray web with a spot of
pressure-sensitive adhesive. In this manner, the tray web size is
minimized, rendering the tray web easier to handle. Once the food
item is loaded, the guard is removed and the flaps can be opened to
a substantially horizontal disposition and an adhesive can be
applied thereto and to the flange in the manner described above. A
stretched lidding web can then be bonded to the adhesive to create
a hermetic seal between the tray web and the lidding web. The
lidding web can be microperforated and additionally can include
printed material on a portion thereof. Following bonding of the
lidding web to the tray web, the flaps may be more rigidly bonded
to the tray web.
[0093] Microperforation of lidding webs may be performed by lasers.
Microperforation of lidding webs can take place before or after
bonding to the tray web. Furthermore, printing in the areas of
microperforations may also take place with microperforation without
hindering the ability of the microperforations to perform as
desired. Suitable laser techniques and methods for use in the
present invention can be provided by the Rofin Company. Information
concerning laser techniques can be located at the Web site
http://www.rofin-sinar.com/home-e.htm. Microperforations as small
as 0.1 mm (0.004 inch) diameter can be provided by these
techniques. Other entities capable of performing suitable
microperforations by laser include Laser Machining Inc. of
Somerset, Wis. Information about Laser Machining Inc. is available
at the Web site http://www.lasermachining.com/company/company.htm.
By use of a carbon dioxide laser, microperforations in the range of
40-400 .mu.m and perforation speeds as high as 500,000 holes per
second can be achieved. While proportions and methods of providing
microperforations have been provided with reference to two makers,
it is to be appreciated that other methods exist which can be used
in the present invention, such methods can include mechanical
methods, such as puncturing the lidding web with pins of suitable
diameter. Other methods can utilize high voltage corona discharge.
The methods of making herein described being merely examples. Other
dimensions of microperforations less than or greater than the
dimensions herein described can be used to practice the present
invention, the dimensions described herein being examples.
[0094] Suitable adhesives for use in the present invention are
known as pressure-sensitive adhesives (PSAs). Suitable adhesives
are provided by the National Starch and Chemical Company of
Bridgewater, N.J. For instance, one example of a suitable adhesive
for use in the present invention, known by the trademark
DURO-TAK34-449A. DURO-TAK34-449A, is a family of hot melt
pressure-sensitive adhesives designed and qualified for direct food
contact. Further information can be obtained from the National
Starch and Chemical Company. However, it should be readily
appreciated that the adhesive disclosed herein is merely one
example of a suitable adhesive for use in the present invention.
Other suitable adhesives are well known to those in the art.
[0095] There are several advantages to using pressure-sensitive
adhesive as opposed to a heat-sealable lidding web. First, PSAs do
not require a heating bank. Pressure-sensitive adhesives are thus
quicker to apply because they do not require a heating or setting
time as is required of heat-sealable materials. Second, by using a
packaging conduit for controlled atmosphere packaging, the use of
vacuum chambers for individually evacuating each tray of oxygen and
substituting a suitable gas is eliminated. Third, the use of
pressure-sensitive adhesives eliminate the need to have a
heat-sealable layer as part of the lidding web composite. This
reduces the amount of scrap material. In some instances,
heat-sealable material is not reusable or recyclable, making the
use of pressure-sensitive adhesives much more economical and
advantageous. If desired however, a heat-sealable lidding web can
be used in the present invention.
[0096] In one aspect of the invention, a tray is loaded with a food
item. The tray is then carried on a conveyor and the flaps are
substantially horizontally disposed so as to extend outwardly from
the tray walls. The tray web of FIG. 6 described above shows one
instance of a tray with horizontally disposed flaps before bonding
of the flaps to the tray walls. A suitable adhesive, such as a
pressure-sensitive adhesive, is then applied to the flange and to
the flaps at locations where desired bonding of the tray web with
the lidding web is to take place. Flaps can be supported by
supports on the conveyor to substantially stay in a horizontal
disposition until desired to be folded and bonded to the tray
walls. The stretched lidding web is brought into contact with the
pressure-sensitive adhesive applied to the flaps and to the tray
flange. The lidding web is then severed in a longitudinal and
transverse manner, thus allowing the flaps with bonded lidding web
thereto to fold in a downward motion. A suitable adhesive is
applied, in one instance, on the outside tray cavity walls and the
flaps are folded and bonded thereto. In one particular embodiment,
the lidding web can be perforated at desired locations such as
described hereinabove or additionally or alternatively, the lidding
web can be provided with printed material on sides of the tray.
[0097] In another embodiment of the present invention, two of the
four flaps of a tray, either two ends or two sides, can be
selectively bonded to the tray cavity walls without a lidding web
bonded to the flaps, while the remaining two flaps left in a
horizontal disposition can be bonded to the lidding web followed by
severing the lidding web and bonding of the flaps with lidding web
to the tray cavity walls. The two flaps that are folded in advance
of this step may or may not be provided with a lidding web bonded
thereto. In any event, when adhesive is provided to the tray
flange, adequate hermetic sealing of the lidding web to the tray
occurs even though the lidding web may not extend to the folded
flaps. In one particular embodiment, a food tray having four flaps
is loaded with a food item. A suitable adhesive, such as a
pressure-sensitive adhesive can be applied to the tray flange and
the two horizontally disposed flaps. A lidding web having
microperforations and printing thereon at specific locations can be
stretched and bonded to the tray flange and the flaps. Suitable
cutting devices can trim the lidding web both longitudinally and
across the tray. The two horizontally disposed flaps are folded in
a downward arcing motion and are bonded to the vertical cavity
walls. In this manner, by first bonding leading and trailing flaps
(FIG. 2), trays are in close and sometimes touching proximity to
one another, thus increasing the capacity of the packaging conduit.
Since two of the four flaps have been provided with a lidding web,
it is convenient to have communication between the tray cavity and
the flap recess on one or both of these longitudinal sides.
[0098] In further aspects of the present invention, in addition to
the lidding web being microperforated, the tray can also be
perforated at strategic locations to increase the exchange of
controlled atmosphere gas with air including oxygen. For instance,
microperforations on the tray web in addition or alternatively to
the lidding web, can be located on the tray cavity walls and the
flap walls to provide some communication between gases from the
tray cavity to the flap recess.
[0099] Many variables can be tested to identify a suitable
configuration and achieve the desired gas exchange rate. For
example, the area, number, and size and placement of
microperforations can be increased or decreased to meet the desired
gas exchange rates, or any combination of these variables. For
instance, these variables independently or in combination can be
manipulated so that the level of oxygen within the tray cavity can
be elevated from less than or about 0.05% (500 ppm) oxygen to
greater than or about 10% (100,000 ppm) oxygen within less than or
about 10 minutes. However, under other circumstances, the level of
oxygen within the tray cavity can be elevated from less than or
about 0.05% (500 ppm) oxygen to greater than or about 3% (30,000)
oxygen within less than or about 15 minutes. The diffusion and gas
exchange rates can vary based on a number of variables. For
instance, the diameter of microperforations can be adjusted to an
optimum, taking into consideration the desired gas exchange rate
and the need to reduce the amount of liquid weep. Other variables
that may be considered is the amount of free space volume within
the tray cavity, the volume of the communication, and the volume of
the flap recess. Greater volumes can add to the time for sufficient
gas exchange to take place. Other variables, not mentioned here are
also considered to affect the gas exchange rate and can be taken
into consideration by varying the area of microperforations, the
amount of microperforations, the spacing between perforations and
the diameter and location of the microperforations, to name but a
few examples. These variables can again be determined
experimentally to meet the desired application. Other variables,
which may or may not be under the control of the designer, may
effect the gas exchange such as temperature, pressure, humidity,
air composition, etc., and can be accommodated in the manner
described.
[0100] Referring now to FIG. 11 another embodiment of a tray web
according to the invention is shown wherein a tray 1100 with cavity
1102 is assembled with an end flap 1104 and side flap 1106 that are
hinged at hinges 1108 and 1110, respectively, with corresponding
third and fourth flaps on the opposite sides of tray 1100, which
cannot be seen in this figure. It is apparent that opposing flaps
can be of similar construction to the ones shown. The side flap
1106 is formed with a series of recesses and channels that connect
the recesses together in a sequence that will inhibit the escape of
liquids, but will allow direct communication of gases there through
when a web material has been stretched and sealed to the flap, and
in the manner as will be described herein below. Side flap 1106 is
formed with a side lower recess 1112 that continues along its full
length close to the lower edge of the flap 1106, as seen in FIG.
11. Side lower recess 1112 is formed with a base and sides so that
a bead of adhesive 1114 can be extruded and deposited along its
full length, or intermittently, or as otherwise may be determined
appropriate. The depth of recess 1112 is such that adhesive bead
1114 does not extend beyond its depth. Adhesive bead 1116 is
extruded onto the flange 1118 and bead 1120 is extruded onto flange
1122. Additional beads 1124 and 1126 are extruded and applied to
flap 1106, and corresponding beads of adhesive are applied to the
opposite end of flap 1106, but cannot be seen in the illustration
of the tray shown in FIG. 11. Beads of adhesive are also applied to
the corresponding locations of the opposing flap on the other side
of tray 1100, but this cannot be seen in FIG. 11. A bead of
adhesive 1128 can also be applied to the outer ends of flap 1104,
and also to the opposite end of flap 1104 as well as to the
opposing flap at the corresponding locations. Beads of adhesive in
all cases are applied at locations that cannot be contacted by
guards or guides that may be used to retain a multiplicity of such
trays with adhesive as they are transferred down a conveyor. Such
guards and guides would be situated parallel to a conveyor used to
transfer the trays, and would therefore not come into contact with
the adhesive beads that have been deposited in recessed channels,
or at the corners and on the radius of the flanges as shown on the
perpendicular side and end planes. A pre-stretched web of lidding
material can therefore be applied with apparatus herein described
such that it contacts substantially all of the adhesive beads that
will then hold the web securely, which can then be cut
appropriately such that the section covering the opening to cavity
1102, the side flap 11064, and the opposing side flap not shown in
FIG. 11. The adhesive used may be a pressure-sensitive adhesive or
other suitable bonding agent as specified herein above, and will
hold the stretched web material in position, retaining its tension,
the web will conform to the flanges 1118, 1122, 1130 and also the
flange of the fourth side opposite to flange 1130, which cannot be
seen. The tension will cause the lidding web to conform to not only
the flanges, but also to the surfaces of flap 1106 in contact with
lidding web.
[0101] Referring now to FIG. 13, which shall be detailed
additionally below, the surface of flap 1106 at surface 1132 and
opposing flap 1134 at surface 1136 have an arcuate shape that
continues in a substantially continuous line from the base of one
flap, upwardly around the surfaces 1138, 1140, and 1142, and across
the entire package to radius 1136. This configuration provides for
conformity of the stretched web to those exposed surfaces around
the recesses and channels, formed into flap, such as flap 1106, and
the corresponding opposite flap 1134.
[0102] Referring again to FIG. 11, channels 1144, 1146, 1148, 1150,
1154, and 1168 connect recesses 1156, 1158, 1160, 1162, 1164, and
1166 together. The series of channels and recesses ends in channel
1144 that is open to the outside. It can therefore be seen, after
application of a web of material that has been bonded to an
adhesive, gas or ambient air can freely follow the channels and the
recesses, and connect to channels 1170, 1171, 1172, and 1174
directly into the cavity 1102 of tray 1100. Channels 1172 and 1174
are formed into the peaks on the inner facing side wall of tray
web. It can also be seen that channels 1148 and 1150, for example,
are arranged at different locations, i.e., at different heights.
Differing channel height is provided to inhibit the escape of any
liquids that may be present in cavity 1102 after packaging. For
example, if a finished package comprising tray, ground beef
contents, and a stretched web lidding material fully assembled, is
turned onto a side, any liquids that may be present will firstly
fill recesses 1176, formed into the inner facing side of the tray
side walls. Assuming that there is sufficient liquid present so as
to fill recesses 1176 to such a level that liquid may enter
channels 1172 and 1174, the liquid would then flow into recess 1156
via channels 1170 and 1171, and most likely be retained in recess
1156 or in any of the recesses extending outward from recess 1156.
The end of channels 1144 and 1178 are exposed to atmosphere, but
the opening is located at a different plane to the outer surface of
flap 1106, and therefore for any liquid to escape from the package
through channels 1144 and 1178, all recesses would need to fill
with such liquid up to the level of the opening of channels 1144
and 1178. However, the package will have to experience all sorts of
twisting and turning such that liquid will escape from a plane
different from the flap plane. However, gases will be capable of
communicating from the outside of the package to the inside of
cavity 1102 freely. It should also be noted that during the normal
handling of a finished package that is constructed in the manner
herein described, will result in a partial squeezing of the tray
vertical side walls and stretch web material, toward each other.
Such an action will cause elevation of internal gas pressure,
therefore expelling some gas along the channels 1144 and 1178.
After gas has been expelled in this manner and the package is
released, the tray sides will relax to their normal position and
cause a lowering of gas pressure within cavity 1102. This will then
cause gas such as ambient atmosphere, to be drawn along channels
1144 and 1178 and toward cavity 1102. This "bellows" action will
enhance the transfer of gases from within cavity 1102 to ambient
atmosphere, and vice versa. Gas will also diffuse more rapidly
along the referenced channels and allow more rapid exchange of
atmospheric oxygen with gases in cavity 1102, and therefore
facilitate the more rapid generation of oxymyoglobin at the surface
of any meat contained therein.
[0103] Referring now to FIG. 12, a side elevation of the tray as
described in association with FIG. 11, is shown. Adhesive strips
1116, 1124, 1126, 1114, 1128, 1120, 1180, 1182, and 1184 are shown
conveniently located so as to provide secure bonding of a stretch
web material that is applied thereto. It should be apparent also
that material not capable of stretching but nevertheless can be put
under tension both longitudinally and laterally, can be used in
practicing the invention. A clear detail of channels 1144, 1146,
1148, 1150, 1154, 1168, 1170, 1171, 1172, and 1174 are shown
connecting. recesses 1156, 1158, 1160, 1162, 1164, and 1166
together to provide a passageway that will allow gases to pass from
point 1186 via all channels and recesses, and to enter at the tray
cavity 1102 at channels 1172 and 1174. Channels 1178, 1188, 1190,
1192, 1194, and 1196 are shown connecting recesses 1156, 1198,
1101, 1103, 1105, and 1107 together to provide a passageway that
will allow gases to pass from point 1178 via all channels and
recesses and to enter at the cavity 1102 at channels 1172 and 1174.
It can be seen that a stretched web of material that has been
applied to the adhesive will enclose cavity 1102 and the channels
and recesses, leaving only openings 1178 and 1186 to communicate
directly with ambient atmosphere from tray cavity 1102.
[0104] Referring now to FIG. 13, an end view of the tray is shown
with adhesive strips shown at 1116, 1124, 1126, 1128, 1111, 1113,
and 1115. Openings 1178 and 1117 are therefore provided when a
stretched web of material is applied and bonded to the adhesive
strips.
[0105] Referring now to FIG. 14A, a plan view illustration and
cross section illustrations of a lidding web stretching and
packaging apparatus is shown. The views shown give detail of a web
stretching apparatus that is arranged to apply a stretched web of
material to trays similar to those described in association with
FIGS. 11, 12, and 13, thereby bonding the stretched web of lidding
material to an adhesive or bonding agent applied to the tray,
generally as described in association with FIGS. 11, 12, and 13.
FIG. 14B, FIG. 14C, and FIG. 14D show detail of cross sections
through the web stretching apparatus at various locations along its
length.
[0106] Referring to FIG. 14A, a web of lidding material 1202 is
gripped at each side edge by a pair of gripping chains 1204 and
1206, and continuously carried forward by the chains. The lidding
web 1202 is unwound from a roll 1208 of source material. The roll
1208 is mounted on a device having a braking mechanism to apply
longitudinal tension on the web as the web is pulled forward. As
the web is carried forward the web engages with two outer cords and
two inner cords. The web 1202 is laterally stretched between the
series of outer and inner cords 1210, 1212, 1214, and 1216.
Longitudinal stretch in web 1202 is induced by applying a
controlled brake to the roll 1208 of material from which web 1202
is unwound so that the speed of roll 1208 is slower than the speed
of the chains 1204, 1206. Web gripping chains 1204 and 1206 apply
tension thereby inducing a longitudinal stretch to a controlled
extent of, for example, 10%, but not exceeding 20%, by carrying the
web forward. Lateral stretch is induced by increasing the distance
between the gripping chains 1204, 1206, and the cords 1214, 1216.
Gripping chains 1204 and 1206, as well as cords 1210, 1212, 1214,
and 1216, are constructed as endless devices to accommodate
continuous processing. Cords 1210, 1212, 1214, and 1216 and chains
1204 and 1206 are also driven by variable speed driving motors,
which are not shown. The web of lidding material 1202 and the
stretching assembly are located directly above a suitable conveyor
1202 carrying loaded trays, such as 1218 and 1220, which can be
similar to those trays described in association with FIGS. 11, 12,
and 13. The cords 1210, 1212, 1214, and 1216 are driven at a
relatively equal and constant speed as is the conveyor carrying the
trays. The cords are retained in a vertical disposition as shown in
FIG. 14D. FIG. 14D shows endless cord 1210, for example, held
captive by retaining bar 1222 and a pivot 1224. Cord assembly,
comprising cord, bar, wheels, and pivots, has a lower and upper run
of cord 1210 trained on two wheels located on either end of the bar
1222 to which the cords are trained in an endless loop. A wheel is
driven by a suitable variable speed driving motor so as to drive
cord 1210 in the required direction, and at any velocity that is
selected.
[0107] Referring to FIG. 14B, it can be seen that gripping chains
1204 and 1206 grip web 1202 at its lateral edges. Cords 1214 and
1216 are below the web 1202 and cords 1210 and 1212 are above the
web 1202. The web is being laterally stretched over and below the
cords as the cords are spaced relatively further apart from each
other and from chains 1204 and 1206, while the web 1202 is held at
its edges by gripping chains 1204 and 1206. As the web 1202 is
carried forward by gripping means 1204 and 1206, the cords 1210,
1212, 1214, and 1216 are in contact with and will stretch web 1202.
It is to be appreciated that rigid or semi-rigid web materials may
undergo little or no stretching. Moreover, even these materials can
be put under longitudinal and lateral tension with the apparatus of
the present invention. As can be seen in FIG. 14A, web edge
gripping means 1204 and 1206 and cords 1210, 1212, 1214, and 1216
converge inwardly toward the longitudinal center of the apparatus.
As gripping mechanisms 1204 and 1206 converge, cord assemblies
1210, 1212, 1214, and 1216 follow a parallel path inwardly toward
the center. As the cords and gripper means converge, cords 1210 and
1212 are angled downwardly and cords 1214 and 1216 are angled
downwardly to bring the lidding web closer to the trays. The
downward angle of cords 1214 and 1216 and the downward angle of
cords 1210 and 1212 are arranged to provide a lateral stretch in
web 1202, and simultaneously alter the profile of an initially flat
web 1202 to that of an inverted channel as shown in FIG. 14C. Cords
1214 and 1216 terminate at locations 1226 and 1228 along the
conduit, respectively; thereby allowing stretched web 1202 to come
in contact with the upper surface of the trays.
[0108] Referring to FIG. 14C, a base 1230 and cover 1232 comprise a
section of a conduit to enclose a section of the web stretching
apparatus wherein the stretched web 1202 has been applied by
allowing cords 1214 and 1216 to terminate. Thus, web 1202 is
allowed to fall to the upper surfaces of tray 1234. Web 1202 is now
in contact with the upper flanges of tray 1234. However, cords 1210
and 1212 are still in contact with the web 1202 on opposing sides
thereof and are at a spaced distance to hold the web 1202 away from
contact with the tray sides. The web 1202 continues to be gripped
at each edge by gripping means 1204 and 1206. Rollers 1236 and 1238
located on opposing sides of the conveyor are provided to apply
pressure in the direction shown by arrows adjacent thereto, and
cause web 1202 to contact the sides of tray 1234. Rollers 1236 and
1238 can be arranged so as to depress web 1202 into the recess
1112, shown in FIG. 11, and to cause contact and therefore bonding
of web 1202 to adhesive 1114 located in the recess. After bonding
web 1202 to tray 1234, the trays are separated from the web.
[0109] Referring now to FIG. 15, an illustration of an apparatus
1300 for biaxially stretching a web of material and applying the
web to trays, as described in association with FIGS. 11, 12, and
13, is illustrated. The apparatus includes a frame 1302 supported
by adjustable legs 1304, 1306, and 1308. An assembly of rollers is
located at an upper location on the frame 1302. A roll of web
material 1310, such materials being described in PCT/US01/45146,
for example, is located at an upper location on the frame 1302. A
suitable lidding web material is plasticized polyvinyl chloride
"pPVC", which is capable of stretching and has memory, i.e., can
expand under tension and then contract once the tension is removed.
However, semi rigid materials, including biaxially oriented
polyester can be used in the invention. One feature of the
apparatus is that it does not substantially allow further
tensioning or relaxation of the initial tension applied to the
lidding webs until only after bonding the lidding webs to the
trays. By not allowing additional tensioning or relaxation of
tension, the lidding webs are not allowed to undergo further
stretching, which could result in smearing of the bonding agent
that may lead to failures of the hermetic seal, or if tension is
relaxed, lidding webs may undergo contraction that may lead to
creases in the web, an unattractive appearance to consumers. A
drive roller 1312 is located adjacent the roll of web material
1310. The drive roller 1312 unwinds the web material 1314 as it
travels over idler rollers 1316 and 1318. Additionally, or
alternatively a second lidding web material 1320 can be laminated
to the first material of roll 1310. The lidding material 1314,
whether single or multi-ply material, travels underneath idler
roller 1318. From idler roller 1318, the lidding material 1314 is
captured at its edges by gripping means, such as gripping chains
1350 and 1352. Gripping chains 1350 and 1352 are positioned on
opposite sides of the lidding material 1314. The gripping chain can
be trained on a longitudinally extending structure assembly wherein
the chains glide over upper and lower surfaces thereof. Gripper
chains can be trained on sprocket wheels located on either end of
the longitudinal structure. One sprocket wheel may be a drive
sprocket where the opposite sprocket is an idler sprocket. A stream
of trays, such as 1322 and 1324, are carried on a conveyor belt
1326 at any suitable speed. Conveyor belt 1326 has a base platform
1327 supporting the conveyor belt 1326. Conveyor belt 1326 can be
connected a variable driver (not shown). The speed of conveyor belt
1326 can be adjusted via the driver.
[0110] Outer right cord assembly 1330, outer left cord assembly
1332, inner left cord assembly 1328, and inner right cord assembly
1340 that cannot be seen are arranged such that web 1314 engages
with the cords, and is stretched as it is carried forward.
[0111] In one embodiment, a vacuum chamber 1334 is attached to
conduits 1336 that are located so as to carry any scrap lidding
material that has been cut and separated from the continuous
lidding material 1314 by a suitable cutting means 1333.
[0112] Referring now to FIGS. 16 and 17, cross-sectional
illustrations of the apparatus of FIG. 15 are illustrated. FIG. 16
shows a cross section of the packaging conduit after the inner cord
assemblies have terminated and only the outer cord assemblies 1330,
1332 remain, while FIG. 17 shows both inner 1340, 1328 and outer
1330, 1332 cord assemblies. Cord assemblies are seen more clearly
comprising an elongated bed, wheels, and cords supported by the
bed, and trained on the wheels at either end of the elongated beds.
Referring to FIG. 17, the conveyor platform 1327 and belt 1326 are
shown carrying trays. Outer cord assemblies 1330 and 1332 are
located alongside the conveyor 1326 on either side of a tray. Inner
cord assemblies 1328 and 1340 are angled downwardly as the cord
assemblies are arranged alongside the conveyor 1327. Cord
assemblies 1328 and 1340 are fitted with endless cords 1329 and
1341. Cords 1329 and 1341 endlessly revolve on cord assemblies 1328
and 1340, respectively. Cords 1329 and 1341 are driven by any
suitable driver. Outer cord assemblies 1330 and 1332 carry a second
set of cords 1331 and 1333, respectively. Outer cord assemblies
1330 and 1332 are angled downwardly as cord assemblies 1330 and
1332 travel alongside the conveyor 1327. Cords 1331 and 1333
endlessly revolve on cord assemblies 1330 and 1332, respectively.
Cords 1331 and 1333 can be driven at any suitable speed by drivers
(not shown). Lidding material 1314 is moved forwardly by gripper
chain assemblies 1350 and 1352 gripping the respective opposite
edges of lidding material 1314. Gripping chain assemblies 1350 and
1352 have suitable gripper chains 1354 and 1356 that hold the edges
of lidding material 1314. Gripping chains 1354 and 1356 can be
trained in an endless fashion about gripping structure assemblies
1350 and 1352, respectively. Gripping chains 1354 and 1356
endlessly revolve on gripping assemblies 1350 and 1352,
respectively. Gripping chains 1354 and 1356 can be driven at any
suitable speed. From the gripping chains 1354 and 1356, lidding
material 1314 is in contact with the lower runs of cords 1331 and
1333 of the outer cord assemblies 1330 and 1332, respectively.
Lidding material 1314 is then in contact with the upper runs of
cords 1341 and 1329 on the inner cord assemblies 1340 and 1328,
respectively. In this fashion, lidding material 1314 is suitably
formed into an inverted channel. The channel created by the
stretched web 1314 has an upper middle portion extending downward
along either side of conveyor so that the inverted channel
surrounds the trays from the top and two sides.
[0113] Referring now to FIG. 16, a cross-sectional illustration of
the stretching apparatus of FIG. 15 is illustrated. FIG. 16 shows
the cross-section of the apparatus 1300 of FIG. 15 where the only
set of cord assemblies that are shown are cord assemblies 1330 and
1332, whereas FIG. 17 shows a cross-sectional illustration of the
stretching apparatus 1300 of FIG. 15 where the two sets of inner
and outer cord assemblies are shown disposed adjacent on opposite
sides of the conveyor. In FIG. 17, outer cord assemblies 1330 and
1332 angle downwardly as they continue from the entrance to the
apparatus to the exit, and inner cord assemblies 1340 and 1328 also
angle downwardly as they travel from the entrance to the exit of
the apparatus. Inner cord assemblies 1340 and 1328 terminate ahead
of outer cord assemblies 1330 and 1332.
[0114] FIG. 16 shows a cross-sectional illustration of the
apparatus of FIG. 15 after termination of the inner cord assemblies
1340 and 1328. Outer cord assemblies 1330 and 1332 are shown in
conjunction with gripping chain assemblies 1350 and 1352. Gripping
chain assemblies 1350 and 1352 have a gripping chain 1354, and
1356, respectively trained in an endless fashion about gripping
chain assemblies 1350 and 1352. The edges of the lidding material
1314 at the edges 1358 and 1360 are held captive to the gripping
chain assemblies 1350 and 1352 by the lower run of the gripping
chains 1354 and 1356, respectively. Lidding material 1314 is
therefore positioned against the lower runs of cords 1331 and 1333.
From the lower runs of cords 1339 and 1332, lidding material 1314
is directed upwards and is in contact with the tray 1362 at the
upper surface in a stretched manner. Outer cord assemblies 1330 and
1332 include cords 1331 and 1333 trained in an endless fashion
about the cord assemblies 1330 and 1332, respectively. Any outer or
inner cord assembly can include drive wheels, such as 1364 and
1366, to drive cords in an endless manner about the cord
assemblies. Depending on whether cord assemblies are the inner or
outer assemblies, the lidding material can be positioned on the
lower or upper run of cord.
[0115] Referring now to FIG. 18, a top plan view of a section of
the stretching apparatus of FIG. 15 is illustrated. Gripping
assemblies 1350 and 1352 are located exterior to the conveyor and
to the inner 1348, 1340 and outer 1330, 1332 cord assemblies. The
web 1314 is carried forward in the direction of the arrow 1376.
Inner cord assemblies 1340 and 1328 terminate ahead of outer cord
assemblies 1330 and 1332. The web 1314 is stretched over inner cord
assemblies 1340 and 1328, and beneath outer cord assemblies 1330
and 1332. Rollers 1370 and 1372 are positioned adjacent conveyor
and in close proximity to passing tray 1374. Rollers 1370 and 1372
are located in the apparatus only after inner cord assemblies 1340
and 1328 have terminated. Rollers 1370 and 1372 are allowed to roll
about an axis that is substantially perpendicular to a horizontal
plane. Rollers 1370 and 1372 are arranged so as to press the web
1314 against the side flaps of the tray 1374.
[0116] Rollers 1370 and 1372 can have an annular raised section or
bump located about the periphery of the roller body. The bump
corresponds to the recess 1112 of the tray illustrated in FIG. 11.
In this manner, the web 1314 can be pushed against the adhesive
bead 1114 located in the recess 1112 of the tray of FIG. 11.
Slitting means 1378 and 1380 cut the excess material from the edges
of the web 1314. The excess material is then removed through
evacuation through conduits 1382 and 1383 after release by the
gripping assemblies 1350 and 1352. Traverse slitting means (not
shown) can be used to cut the web 1314 in a traverse direction
between trays.
[0117] Referring now to FIG. 19, a three-dimensional view of the
web stretching apparatus is illustrated. A section of the web 1314
has been deleted so as to show a clear view of the apparatus. Tray
1325 is transported on the conveyer belt 1326 in the direction
shown by the arrow 1323. Gripping assemblies 1350 and 1352 release
the web 1314 after slitters 1378 and 1380 have removed the excess
web material. The excess material is removed through evacuation
through conduits 1382 and 1383.
[0118] Referring now to FIGS. 30A-34 collectively, another
embodiment of a packaging apparatus for biaxially stretching a
lidding web material prior to bonding to a tray web, is
illustrated. This embodiment of the packaging apparatus of FIGS.
30-34 is similar to the apparatus described in association with
FIGS. 14-19. However, more detail is provided with regard to one
embodiment of gripping means. As shown in FIG. 31, the gripping
means 3100 comprises upper and lower jaws 3102 and 3104,
respectively. The upper jaw 3102 includes a portion extending
horizontally at an upper surface. The portion extends vertically
downward to make contact with an elastomeric rubber rod 3106. On
the opposite side, a vertical arm connects the upper jaw to a
pivoting mechanism 3108. The lower jaw 3104 holds the rubber rod
3106. A suitable spring (not shown) biases the upper and lower jaws
into contact. The upper jaw 3102 can be actuated to open, to allow
insertion of a lateral edge of a lidding web and to close, thus
gripping the lidding web between the end of the upper jaw and the
rubber rod 3106. It is to be appreciated that the operation of all
other gripping means is similar. Also shown in the alternate
embodiment is the web being gripped by the upper portions of the
gripping chains rather than the lower portions, as earlier
described. The separate embodiments illustrate how different
arrangements of the inner and outer cords and the web gripping
chains can be configured for the purpose of achieving a biaxially
stretched lidding web prior to bonding to a tray.
[0119] Referring now to FIG. 20, a front elevation illustration of
an alternate embodiment of a stretch packaging apparatus that has
been constructed for the purpose of sealing a biaxially stretched
web of material to a continuously moving stream of packaging trays,
with goods loaded therein, is shown. One embodiment of the
packaging apparatus includes multiple horizontal conveyors 2033,
2026, 2023, and 2019. Horizonal conveyors 2033, 2026, 2023, and
2019 are arranged to carry loaded packaging trays 2000, 2034, 2017,
2018, and 2030 in the machine direction shown from left to right in
FIG. 20. The conveyors 2019, 2023, 2026, and 2033 are enclosed from
the exterior in an enclosure 2001. The enclosure is supported by
legs 2031, 2025, and 2021. The enclosure 2001 contains a selected
gas provided in the interior space 2035 within the enclosure 2001.
The gas pressure inside the enclosure 2001 can be greater than the
ambient atmospheric pressure. The gas may include blends of gases
having a majority of the gas being carbon dioxide, carbon monoxide,
or nitrogen, for example. However, other embodiments use oxygen
atmospheres having oxygen amounts that may be greater than the
amounts of oxygen found in the air. Each conveyor section can have
one idler roller and a drive roller disposed on either end of the
conveyor. Conveyor 2033 is driven by drive roller 2032. Conveyor
2026 is driven by drive roller 2037. Conveyor 2023 is driven by
drive roller 2022. Conveyor 2019 is driven by a roller not shown,
and wherein the drive roller is mounted at the opposite end of
idler roller 2020. Conveyors 2033, 2023 and 2019 travel at a rate
faster than the centrally located conveyor 2026. The variation in
conveyor speed facilitates the transfer of trays such as 2000 and
2034 onto conveyor 2026, so as to maintain a space between said
trays when on conveyor 2033, however when transferred to conveyor
2026, the trays 2030 and 2036 will contact each other and the trays
adjacent thereto.
[0120] The enclosure 2001 is connected to a backing plate 2013,
fixed to an upper portion of the enclosure 2001. A web unwinding
mechanism is mounted to the backing plate 2013. The source of a web
material 2006 is one of two rolls of web material 2039 and 2012
that are mounted to the backing plate 2013, enabling lidding web
material 2006 to be unwound therefrom. The web 2006 is wound over
idler rollers 2010, 2005, 2004 and 2029. Tensioning of web 2006 is
facilitated by surface drive mechanism 2011. Surface drive
mechanism includes a drive roller connected to an arm 2009 which
pivots about pivot 2040, enabling an alternative drive position
wherein drive roller at position 2008 engages with the surface of
web roll 2039. However, as shown in FIG. 20, web 2006 is unwound
from roll 2012. Web 2006 is carried over idler rollers 2010, 2005,
2004, and 2029. The lateral edges of web 2006 are gripped by
gripping mechanisms that will be described below. Gripping
mechanisms pull the web 2006 in the same direction as the conveyor
direction. As the web 2006 is pulled in the conveyor direction,
tensioning by surface drive mechanism 2011 can induce longitudinal
stretching of stretchable materials. Surface drive mechanism can
drive the speed of the web roll 2012 at a slower speed than the
speed of the conveyor so as to induce a controlled rate of stretch
to the web. Alternatively, rigid or semi-rigid materials can be
used instead of stretchable materials and would be placed under
tension but may have little or no stretch and speeds at surface
drive mechanism and conveyor can be substantially the same. Web
2006 enters enclosure 2001 through narrow opening 2002. The
pressure in enclosure 2001 prevents atmospheric air from entering
the enclosure 2001. Web stretching subassemblies, described below,
are mounted to a pair of horizontally disposed timing belts on
opposite sides of the conveyor, and are driven so as to carry web
2006 along a path that is denoted by line 2027. The web is
eventually brought to the level of the trays. Pressure-sensitive
adhesive is applied to all trays, including 2000 and 2034. Web 2006
will be stretched longitudinally and laterally before bonding to
trays. After bonding, a cutting mechanism 2015 is located above the
continuous stream of loaded trays such that blade holder 2014
reciprocates in a hunting motion parallel with the conveyor
direction along a retaining linear bearing to sever the lidding web
2006 while the trays move forward, without stopping to sever the
web. Blades held in blade holder 2014, enable lateral cutting of
web 2006, after bonding to trays wherein the severing occurs
between each tray. Blades held by blade holder 2014 can be
controlled with a suitable vision system that recognizes the
location between each tray, and automatically positions the blades
to enable lateral cutting of the web between each tray.
[0121] Referring now to FIG. 21, a plan view illustration of a web
stretching assembly that can be mounted to a packaging apparatus is
shown. The apparatus of the present invention can biaxially stretch
a web, meaning tension is applied to the web both longitudinally
and laterally. The tension reduces any creases or ripples that are
unattractive to the consumer and also enables tensioned contact
with goods in the tray cavity, at the central portions thereof. The
web stretching apparatus includes web stretching subassemblies,
timing belts, cam followers, and cam tracks. The web stretching
assembly comprises a plurality of similarly constructed web
stretching subassemblies attached to a pair of timing belts. Web
stretching subassemblies are also in contact with the cam tracks,
described below. The cam tracks allow for and guide the operation
of the web stretching subassemblies. A continuous stream of loaded
trays, including 2110 and 2117, are carried on horizontal conveyors
2100 in a left to right direction. A series of web stretching
subassemblies, including 2103 and 2114, are mounted onto a pair of
right and left side timing belts 2106 and 2113. The timing belts
2106 and 2113 are, in turn, mounted to a common drive pulley and
suitable idler pulley fixtures. Cam tracks 2104 and 2115 are
constructed in a fixed position adjacent the timing belts. The web
stretching subassemblies, including 2103 and 2114, are designed
with cam follows that ride on the cam tracks. Cam tracks are
designed to follow a particular path that will direct cams and
shafts attached thereto to reciprocate laterally and to open and
close a web gripping jaw on every web stretching subassembly. The
web stretching subassemblies are designed to grip lateral edges of
web 2102 and apply lateral and longitudinal tension to the web such
that its width is reduced as shown at locations 2105 and 2118 in
FIG. 21, due to the longitudinal stretching. Web stretching
subassemblies are mounted to and carried on the timing belts, and
can therefore tension and also stretch web 2102 laterally and over
trays carried on conveyors 2100. A lateral cutting mechanism is
shown wherein blade holder 2108 is mounted to linear bearing 2109.
A reciprocating drive mechanism is described below in association
with FIG. 27 wherein an assembly of lateral cutting blades enable
cutting lateral cutting of the web as required. After lateral
cutting of the web, finished trays, such as 2111 and 2112, are
transferred by conveyor 2119 to further processing or packaging
operations, that may include packaging in a master container or any
other suitable container.
[0122] Referring now to FIG. 22, a three dimensional illustration
of a web stretching subassembly, such as web stretching subassembly
2103 of FIG. 21, is shown. The web stretching subassembly 2103 is
intended for use in conjunction with a plurality of similar devices
wherein all such subassemblies are mounted onto a timing belt. At
least two timing belts 2106 and 2113 are arranged to travel in a
horizontal disposition on either side of a conveyor as shown in
FIG. 21.
[0123] A section of a timing belt 2207 is shown with a base plate
2212 attached on an upper surface of the timing belt. The base
plate 2212 is rigidly fitted to an end plate 2218 and at the
opposing end of the base plate, a block 2206, is fixed rigidly to
the base plate 2212. The block 2206 has apertures to accommodate a
number of shafts 2209, 2208, and 2296 therethrough. Shafts 2208 and
2296 traverse the block 2206 and extend between upper 2297, middle
2205, and lower 2204 cam track plates. Shafts 2208 and 2296 can be
actuated horizontally to operate the web stretching subassembly, as
dictated by the direction of the cam tracks in the cam track
plates. The shaft 2209 is threaded at both ends, and nuts 2213 and
2214 hold the shaft 2209 in a rigid and horizontal position with
base plate 2212 and timing belt section 2207. A web gripping
subassembly 2250 is provided between rigid block 2206 and end plate
2218. The web gripping subassembly 2250 is a part of the larger web
stretching subassembly 903. The web gripping subassembly can slide
on shaft 2209. The web gripping subassembly 2250 can move in the
lateral direction between the extremes of the block 2206 and the
end plate 2218. The web gripping subassembly 2250 has a machined
block 2215 centrally disposed between the plate 2295 and jaw block
2216 and jaw end plate 2217 all arranged in a relatively fixed
position to each other, and held together by shaft 2208 with nut
2289 tightened onto a threaded end. Shaft 2208 also connects the
web gripping subassembly 2250 to block 2206. Upper gripping jaw
2210 is mounted to pivot at location 2211. When closed, upper
gripping jaw 2210, contacts a cylindrical rubber member 2290,
manufactured from a suitable extruded or molded rubber compound.
Upper jaw 2210 can thusly be actuated open and closed, so that in
the closed position, jaw 2210 and rubber member 2290 are compressed
against one another. Block 2215 and end plate 2295 are in touching
proximity to upper surface 2220 of base plate 2212 and block 2215
and plate 2295 can slide or otherwise move along the upper surface
of the base plate 2212. Shaft 2296 is attached to upper gripping
jaw 2210 at the pivot pin 2291 via a pair of connecting arms 2292
and coupling 2221. A spring 2294 is mounted onto the shaft between
the plate 2295 and the upper gripping jaw 2210, so as to exert
suitable expanding pressure between plate 2295 and shaft end 2221.
Spring 2294 is arranged such that in a free condition, expanding
pressure provided by spring 2294 causes upper gripping jaw 2210 to
close suitably against rubber section 2290, and in a manner that
will facilitate the gripping of an edge of a flexible web material,
including thin gauge pPVC. Shaft 2296 is fitted with a pair of cam
followers 2298, at the end opposite of the jaw 2210, and arranged
to engage with cam tracks 2299 and 2200, machined in upper cam
track plate 2297 and middle cam track plate 2205. Similarly, a pair
of cam track followers 2203 are arranged to engage with cam tracks
2201 and 2202, machined in middle cam track plate 2205 and lower
cam track plate 2204. It is apparent that cam track plates 2297,
2205 and 2204 only constitute a portion of the total cam track
structure wherein the cam track structure can lie adjacent the web
as shown in FIG. 21. It is also apparent that cam track plates are
relatively stationary to the web stretching subassembly, so that
the web stretching subassembly will travel along and the operation
of individual web stretching assemblies will be dictated by the cam
tracks. A plurality of cam track plates may extend along on both
sides of the horizontal conveyors for any length that is necessary
to apply lidding web to trays. Cam followers 2203 on shaft 2208
will ride in cam tracks 2201 and 2202, and will correspondingly
cause web gripping subassembly jaw and blocks attached therewith,
to move between end plate 2218 and end block 2206. Cam tracks 2299
and 2200, wherein cam followers 2298 ride within, can be arranged
to follow a similar path to cam tracks 2201 and 2202, and therefore
maintain jaw 2210 in its gripping mode as required. However, when
cam tracks 2299 and 2200 diverge outwardly (i.e., distally, web
stretching subassembly 2103 has a distal end away from the gripping
jaw subassembly 2250, and a proximal end, toward the jaw gripping
subassembly) relative to cam tracks 2201 and 2202, jaw 2210 will
separate from the opposing rubber member 2290 allowing any web
thereby gripped, to be released.
[0124] Referring now to FIG. 23, a cross-sectional view A--A
through the horizontal conveyor assembly, as detailed in FIG. 21,
is shown. A pair of web stretching subassemblies 2350 and 2352, are
shown on opposite sides of a tray 2314. While operation of only one
web stretching subassembly will be described, the operation is
mirrored in the directly opposite web stretching subassembly. Cam
tracks 2303 with cam followers 2302, and cam tracks 2300 with cam
followers 2301, are shown in relative locations that compress
spring 2308, thereby opening jaw 2310 to allow web 2315 to be
placed upon rubber member 2311, and on the opposing similar rubber
member on the opposite side of center line 2353. When cam tracks
2303 move outward relative to cam tracks 2301, the web gripping jaw
2310 will open. Similar cam tracks operate in a similar manner on
web stretching subassembly 2350 Conveyor belts 2316 with the
packaging tray 2314 mounted thereupon, are disposed to follow a
path between opposing web stretching subassemblies 2350 and 2352.
The pair of opposing web stretching subassemblies 2350 and 2352 are
mounted onto correspondingly opposing timing belts 2305 and 2306,
respectively, and are shown with web gripping jaws 2310 and 2319 in
an open disposition. Web 2315 is provided, having a flat width
proportionately shorter than the width as provided in roll form.
This is due to the extent that when longitudinal tension is
applied, the width of the web 2315 will be decreased if stretch is
induced. However, the width of web 2315 can be increased by web
stretching subassemblies applying lateral tension.
[0125] Referring now to FIG. 24, a cross-sectional view B--B
through the horizontal conveyor assembly as detailed in FIG. 21 is
shown. It can be seen that cam tracks 2303 with cam followers 2302
have moved inwardly relative to cam tracks 2301, and are in
vertical alignment to cam tracks 2301, with cam followers 2300.
Similar cam tracks operate in similar manner on web stretching
subassembly 2350. Thus, jaws 2310 and 2319 have closed thereby
gripping web 2315 between upper gripping jaws 2310 and 2319 and
corresponding rubber members 2311, and 2312. However, web 2315 can
be stretched laterally by simultaneously outwardly directing cam
tracks 2303 and 2301, thereby outwardly directing the web gripping
subassemblies in relation to the tray, while maintaining web
gripping mode and thereby increasing the lateral tension of web
2315, prior to contact with tray 2314. It should be noted that any
stretching of web 2315, most preferably will occur prior to the web
contacting any bonding agent on the packaging tray 2314. Web
gripping mode of jaws 2310 and 2319 is in part facilitated by
springs 2308 and 2354. Springs 2308 and 2354 have expanded such
that jaw 2310 and the corresponding opposing jaw 2319, are both
biased in gripping contact with rubber member 2311 and the opposing
rubber member 2312. Web 2315 accordingly, is gripped at both
lateral edges by gripping jaws 2310 and 2319. Timing belt 2305 and
opposing timing belt 2390, can remain in a horizontally disposed
path and driven by a common variable speed drive such that all web
stretching subassemblies follow the same path. Cam track plates can
be stationary relative to timing belts, however, cam tracks will
follow the path suited for gripping and stretching web. Packaging
tray 2314 travels parallel to and at the same speed as timing belts
2305 and 2390 so as to avoid moving web once web has made contact
with a bonding agent. Blocks 2391 and 2324 are relatively inwardly
positioned on base plates 2304 and 2321, respectively, and lateral
tensioning will not begin until blocks 2391 and 2324 are biased
outwardly with jaws 2310 and 2319 in the gripping mode.
Alternatively, the lateral tension can be applied by fixed web
gripping subassemblies, and directing the timing belts outwardly
relative to the center.
[0126] Referring now to FIG. 25, a cross-sectional view C--C
through horizontal conveyor assembly as detailed in FIG. 21, is
shown. Gripping jaws 2310 and the opposing jaw 2319 are shown in
the gripping, closed position mode. Blocks 2391 and 2324 have been
biased outward, thus putting lateral tension on web 2315 and
stretching web 2315. Web 2315 is also now in contact with the
uppermost surfaces of tray 2314, as a consequence of the changing
relative position of conveyor belts 2316, and timing belts 2305 and
2390. Pressure-sensitive adhesive beads have been applied to
selected locations of tray 2314, as described in association with
FIGS. 11 through 13, and are in position to allow bonding contact
with web 2315. Web stretching subassemblies 2350 and 2352 travel at
substantially the same speed as conveyor belts 2316 to avoid
smearing adhesive beads.
[0127] Referring now to FIG. 26, cross-sectional view D--D through
horizontal conveyor assembly of FIG. 21, is shown. It can be seen
that web 2315 has been wrapped around the upper surface and
vertical sides of tray 2314 by controlling the relative position of
timing belts 2305 and 2390 and conveyor 2316, and also by the
appropriate guidance of the web gripping subassemblies. The web
2315 is wrapped under the lower corners of tray 2314, and in such a
manner that web 2315 makes full bonding contact with adhesive beads
applied as described in association with FIGS. 11 through 13.
However, once initial contact is made between web 2315 and a
bonding agent on the tray, the tension on the web is neither
increased or reduced so as to cause the web neither to stretch or
contract so as to avoid causing smearing of the adhesive or the
formation of creases in the web. Thus, once initial contact between
web 2315 and a bonding agent is made, the web width or length is
substantially maintained constant while the web is being bonded to
the tray. It should be noted that timing belts 2305 and 2390 are
held captive by drive and idler pulleys, mounted at opposite ends.
However, cam tracks have been arranged to direct web gripping
subassemblies inward, along shafts 2306 and 2391. In this way,
gripping jaws 2310 and 2319 can be positioned on the underside of
the packaging tray 2314.
[0128] Referring now to FIG. 27, cross-sectional view E--E through
horizontal conveyor assembly detailed in FIG. 21 is shown. As can
be seen, the relative position of cam tracks 2303 with cam
followers 2302 have moved outward relative to cam tracks 2301 with
cam followers 2300 and are not vertically aligned but are arranged
so as to fully withdraw and open jaw 2310, and the corresponding
cam tracks and cam followers releasing opposing jaw 2319. Opening
jaws 2310 and 2319 allows sufficient clearance for lateral cutting
mechanism 2392, with vertical cutting blades 2393 and 2394,
attached thereto, and movable in the manner as indicated by the
adjacent arrow. Lateral blade 2392 is mounted to a reciprocating
mechanism that follows a hunting motion, and is associated with a
vision system, or an alternative mechanism, that enables the
alignment of cutting blades with the space between each tray. Thus,
cutting mechanism 2392 will reciprocate upwards and downwards as
well as forwards and backwards. An alternative mechanism enables
the synchronized release of the stretched web and withdrawal of the
web stretching subassemblies; the withdrawal of selected
subassemblies occurring only at locations in the vicinity of where
the lateral cutting is to take place. The remaining web stretching
subassemblies continue to grip the web upstream and downstream of
the only withdrawn subassemblies. The remaining subassemblies are
withdrawn after the web has bonded to the tray. This alternative
mechanism is not shown, however in this instance, cam followers and
cam tracks can be arranged to open the jaws and withdraw the jaw
gripping subassemblies only at locations between trays where
cutting is to occur. This location can be determined by a vision
system utilizing a suitable form of radiation, including visible
light, for example. Other alternative cutting devices can be used,
utilizing high pressure fluids or heat, for example.
[0129] Referring now to FIG. 28, cross-sectional view F--F through
horizontal conveyor assembly as detailed in FIG. 21 is shown. It
can be seen that complete separation of the web stretching
subassemblies 2350 and 2352 and tray 2314 has occurred. The web
gripping jaws are open and are in the withdrawn position. This
enables the transfer of separated trays, such as 2314, along
conveyor 2316, and away from the web stretching and bonding section
of the apparatus.
[0130] While the preferred embodiment of the invention has been
illustrated and described, it will be appreciated that various
changes can be made therein without departing from the spirit and
scope of the invention.
* * * * *
References